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987158-UIM-D-0616 MODULATING ECM RESIDENTIAL GAS FURNACE MODELS: TPLC*C, YPLC*C, CPLC*C, LPLC*C (80% AFUE Multi-position / Low NOx) INSTALLATION MANUAL LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 24 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . . 31 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . 32 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 LIST OF FIGURES Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Horizontal Application (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7 Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 8 Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical Wiring 12 Furnace Control Board – Communications Connections . . . . . . . . . 13 Modulating Furnace with Communicating AC or HP . . . . . . . . . . . . 14 Modulating Furnace with Communicating Thermostat and Non-communicating AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace . . . . . . . 17 Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Combustion Airflow Path Through The Furnace Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . 23 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 LIST OF TABLES Unit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an Upflow Configuration) . . . . 4 Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 8 Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 9 High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 12 Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . . . . . 29 These high efficiency, compact units employ induced combustion, reli- able hot surface ignition and high heat transfer aluminized tubular heat exchangers. The units are factory shipped for installation in upflow or horizontal applications and may be converted for downflow applica- tions. These furnaces are designed for residential installation in a basement, closet, alcove, attic, recreation room or garage and are also ideal for commercial applications. All units are factory assembled, wired and tested to assure safe dependable and economical installation and oper- ation. These units are Category I listed and may be common vented with another gas appliance as allowed by the National Fuel Gas Code. SECTION I: SAFETY This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury. Understand and pay particular attention to the signal words DANGER, WARNING, or CAUTION. DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate injury . It is also used to alert against unsafe practices and hazards involving only property dam- age.

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Page 1: INSTALLATION MANUAL - Johnson Controls

MODULATING ECM RESIDENTIAL GAS FURNACEMODELS:TPLC*C, YPLC*C, CPLC*C, LPLC*C(80% AFUE Multi-position / Low NOx)

INSTALLATION MANUAL

LIST OF SECTIONSSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 24

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . . . . .31REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .32REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . .32WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

LIST OF FIGURESDuct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 6Horizontal Application (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . 7Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . 8Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Horizontal Left or Right application (Right Shown) . . . . . . . . . . . . . . 8Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Electrical Wiring 12Furnace Control Board – Communications Connections . . . . . . . . . 13Modulating Furnace with Communicating AC or HP . . . . . . . . . . . . 14Modulating Furnace with Communicating Thermostat and Non-communicating AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace . . . . . . .17Thermostat Chart - Single Stage Heat Pump – Variable Speed orPSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Combustion Air Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Combustion Airflow Path Through The Furnace Casing to the Burner Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . .23Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

LIST OF TABLESUnit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an Upflow Configuration) . . . . 4Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . . . . 8Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . . . . 9High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . 12

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . . . .22Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . . . . .26Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . . . . .29

These high efficiency, compact units employ induced combustion, reli-able hot surface ignition and high heat transfer aluminized tubular heatexchangers. The units are factory shipped for installation in upflow orhorizontal applications and may be converted for downflow applica-tions.These furnaces are designed for residential installation in a basement,closet, alcove, attic, recreation room or garage and are also ideal forcommercial applications. All units are factory assembled, wired andtested to assure safe dependable and economical installation and oper-ation.These units are Category I listed and may be common vented withanother gas appliance as allowed by the National Fuel Gas Code.

SECTION I: SAFETY

This is a safety alert symbol. When you see this symbol onlabels or in manuals, be alert to the potential for personalinjury.

Understand and pay particular attention to the signal words DANGER,WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if notavoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation, which, if notavoided may result in minor or moderate injury. It is also used toalert against unsafe practices and hazards involving only property dam-age.

987158-UIM-D-0616

Page 2: INSTALLATION MANUAL - Johnson Controls

987158-UIM-D-0616

SPECIFIC SAFETY RULES AND PRECAUTIONS1. Only Natural gas or Propane (LP) gas are approved for use with this

furnace.

2. Install this furnace only in a location and position as specified inthese instructions.

3. A gas-fired furnace for installation in a residential garage must beinstalled as specified in these instructions.

4. Provide adequate combustion and ventilation air to the furnacespace as specified in these instructions.

5. Combustion products must be discharged outdoors. Connect thisfurnace to an approved vent system only, as specified in SECTIONVII of these instructions.

6. Test for gas leaks as specified in these instructions.

7. Always install the furnace to operate within the furnace’s intendedtemperature rise range. Only connect the furnace to a duct systemwhich has an external static pressure within the allowable range, asspecified on the furnace rating plate.

8. When a furnace is installed so that supply ducts carry air circulatedby the furnace to areas outside the space containing the furnace, thereturn air shall also be handled by duct(s) sealed to the furnace cas-ing and terminating outside the space containing the furnace.

9. It is permitted to use the furnace for heating of buildings or structuresunder construction where the application and use must comply withall manufacturer’s installation instructions including:

• Proper vent installation;• Furnace operating under thermostatic control;• Return air duct sealed to the furnace;• Air filters in place;• Set furnace input rate and temperature rise per rating plate

marking;• Means for providing outdoor air required for combustion;• Return air temperature maintained between 55ºF (13ºC) and

80ºF (27ºC);• The air filter must be replaced upon substantial completion of

the construction process;• Clean furnace, duct work and components upon substantial

completion of the construction process, and verify furnace-operating conditions including ignition, input rate, temperaturerise and venting, according to the manufacturer’s instructions.

10.When installed in a Non-HUD-Approved Modular Home or buildingconstructed on-site, combustion air shall not be supplied from occu-pied spaces.

11.The size of the unit should be based on an acceptable heat loss cal-culation for the structure. ACCA, Manual J or other approved meth-ods may be used.

12.When moving or handling this furnace prior to installation, alwaysleave the doors on the furnace to provide support and to preventdamage or warping of the cabinet. When lifting the furnace by thecabinet, support the ends of the furnace rather than lifting by thecabinet flanges at the return air openings (bottom or sides) or supplyair opening.

13.When lifting the furnace, it is acceptable to use the primary heatexchanger tubes as a lifting point provided that the tubes are lifted atthe front of the heat exchangers where attached to the vestibulepanel. Do not use the top return bend of the heat exchangers as lift-ing points as the tubes may shift out of position or their locationbrackets/baffles.

SAFETY REQUIREMENTS

• Refer to the unit rating plate for the furnace model number, andthen see the dimensions page of this instruction for return air ple-num dimensions in Figure 13. The plenum must be installedaccording to the instructions.

• Provide clearances from combustible materials as listed underClearances to Combustibles.

• Provide clearances for servicing ensuring that service access isallowed for both the burners and blower.

• These models ARE NOT CSA listed or approved for installationinto a HUD Approved Modular Home or a Manufactured(Mobile) Home.

• This furnace is not approved for installation in trailers or recre-ational vehicles.

• Furnaces for installation on combustible flooring shall not beinstalled directly on carpeting, tile or other combustible materialother than wood flooring.

• Check the rating plate and power supply to be sure that the elec-trical characteristics match. All models use nominal 115 VAC, 1Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE130 VOLTS.

• Furnace shall be installed so the electrical components are pro-tected from water.

• Installing and servicing heating equipment can be hazardous dueto the electrical components and the gas fired components. Onlytrained and qualified personnel should install, repair, or servicegas heating equipment. Untrained service personnel can performbasic maintenance functions such as cleaning and replacing theair filters. When working on heating equipment, observe precau-tions in the manuals and on the labels attached to the unit andother safety precautions that may apply.

WARNINGImproper installation may create a condition where the operation ofthe product could cause personal injury or property damage.Improper installation, adjustment, alteration, service or maintenancecan cause injury or property damage. Failure to carefully read andfollow all instructions in this manual can result in furnace mal-function, death, personal injury and/or property damage. Only aqualified contractor, installer or service agency should install thisproduct.

WARNINGFIRE OR EXPLOSION HAZARDFailure to follow the safety warnings exactly could result in seriousinjury, death or property damage.Never test for gas leaks with an open flame. Use a commerciallyavailable soap solution made specifically for detection of leaks tocheck all connections. A fire or explosion may result causing propertydamage, personal injury or loss of life.

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IMPORTANTDuring installation, doors must remain on the furnace whenmoving or lifting.

CAUTIONThis product must be installed in strict compliance with the installationinstructions and any applicable local, state, and national codesincluding, but not limited to building, electrical, and mechanical codes.

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2 Johnson Controls Unitary Products

Page 3: INSTALLATION MANUAL - Johnson Controls

987158-UIM-D-0616

COMBUSTION AIR QUALITY (LIST OF CONTAMINANTS)The furnace requires OUTDOOR AIR for combustion when the furnaceis located in any of the following environments.

• Restricted Environments

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft rooms

• Furnaces installed near chemical storage areas

• Chemical exposure

The furnace requires OUTDOOR AIR for combustion when the furnaceis located in an area where the furnace is being exposed to the follow-ing substances and / or chemicals.

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

When outdoor air is used for combustion, the combustion air intake ductsystem termination must be located external to the building and in anarea where there will be no exposure to the substances listed above.

CODES AND STANDARDSFollow all national, local codes and standards in addition to this installa-tion manual. The installation must comply with regulations of the serv-ing gas supplier, local building, heating, plumbing, and other codes. Inabsence of local codes, the installation must comply with the nationalcodes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for thefollowing, using the latest edition available:

STEP 1 -Safety• US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and

the Installation Standards, Warm Air Heating and Air ConditioningSystems ANSI/NFPA 90B

• CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-ral Gas and Propane Installation Codes (NSCNGPIC)

STEP 2 -General Installation• US: Current edition of the NFGC and NFPA 90B. For copies, con-

tact the National Fire Protection Association Inc.Batterymarch ParkQuincy, MA 02269

or for only the NFGC, contact the American Gas Association, 400 N. Capital, N.W. Washington DC 20001

or www.NFPA.org

• CANADA: NSCNGPIC. For a copy contact:Standard Sales, CSA International178 Rexdale BoulevardEtobicoke, (Toronto) Ontario Canada M9W 1RS

STEP 3 -Combustion and Ventilation Air• US: Section 5.3 of the NFGC, air for Combustion and Ventilation• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply

for Appliances

STEP 4 -Duct Systems• US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning ContractorsAssociation National Association (SMACNA), or American Soci-ety of Heating, Refrigeration, and Air Conditioning Engineers(ASHRAE) 1997 Fundamentals Handbook Chapter 32.

STEP 5 -Acoustical Lining and Fibrous Glass Duct• US and CANADA: Current edition of SMACNA and NFPA 90B as

tested by UL Standard 181 for Class I Rigid Air Ducts

STEP 6 -Gas Piping and Gas Pipe Pressure Testing• US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes• CANADA: NSCNGPIC Part 5

STEP 7 -Electrical Connections• US: National Electrical Code (NEC) ANSI/NFPA 70• CANADA: Canadian Electrical Code CSA C22.1

These instructions cover minimum requirements and conform to exist-ing national standards and safety codes. In some instances theseinstructions exceed certain local codes and ordinances, especiallythose who have not kept up with changing residential and non-HUDmodular home construction practices. These instructions are requiredas a minimum for a safe installation.

WARNINGThe furnace area must not be used as a broom closet or for any otherstorage purposes, as a fire hazard may be created. Never store itemssuch as the following on, near or in contact with the furnace.

1. Spray or aerosol cans, rags, brooms, dust mops, vacuumcleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning com-pounds; plastic items or containers; gasoline, kerosene, ciga-rette lighter fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other painting compounds.4. Paper bags, boxes or other paper products

Never operate the furnace with the blower door removed. To doso could result in serious personal injury and/or equipmentdamage.

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Johnson Controls Unitary Products 3

Page 4: INSTALLATION MANUAL - Johnson Controls

987158-UIM-D-0616

INSPECTIONAs soon as a unit is received, it should be inspected for possible dam-age during transit. If damage is evident, the extent of the damageshould be noted on the carrier’s freight bill. A separate request forinspection by the carrier’s agent should be made in writing. Also, beforeinstallation, the unit should be checked for screws or bolts which mayhave loosened in transit. There are no shipping or spacer bracketswhich need to be removed from the interior of this unit.

FURNACE LOCATION AND CLEARANCESThe furnace shall be located using the following guidelines:1. Where a minimum amount of air intake/vent piping and elbows will

be required.

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available.

4. Where it will not interfere with proper air circulation in the confinedspace.

Installation in freezing temperatures:1. Furnace shall be installed in an area where ventilation facilities pro-

vide for safe limits of ambient temperature under normal operatingconditions.

2. Do not allow return air temperature to be below 55º F (13° C) forextended periods. To do so may cause condensation to occur in themain heat exchanger, leading to premature heat exchanger failure.

Clearances for access/service:Ample clearances should be provided to permit easy access to the unit.The following minimum clearances are recommended:

1. Twenty-four (24) inches (61 cm) between the front of the furnaceand an adjacent wall or another appliance, when access is requiredfor servicing and cleaning.

2. Eighteen (18) inches (46 cm) at the side where access is requiredfor passage to the front when servicing or for inspection or replace-ment of flue/vent connections.

In all cases, accessibility clearances shall take precedence over clear-ances for combustible materials where accessibility clearances aregreater.

Installation in a residential garage:A gas-fired furnace for installation in a residential garage must beinstalled so the burner(s) and the ignition source are located not lessthan 18 inches (46 cm) above the floor, and the furnace must be locatedor protected to avoid physical damage by vehicles.

FOR FURNACES INSTALLED IN THE COMMON-WEALTH OF MASSACHUSETTS ONLYFor all side wall horizontally vented gas fueled equipment installed inevery dwelling, building or structure used in whole or in part for resi-dential purposes, including those owned or operated by the Com-monwealth and where the side wall exhaust vent termination is lessthan seven (7) feet above finished grade in the area of the venting,including but not limited to decks and porches, the following require-ments shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At thetime of installation of the side wall horizontal vented gas fueledequipment, the installing plumber or gasfitter shall observe that ahard wired carbon monoxide detector with an alarm and batteryback-up is installed on the floor level where the gas equipment isto be installed. In addition, the installing plumber or gasfitter shallobserve that a battery operated or hard wired carbon monoxidedetector with an alarm is installed on each additional level of thedwelling, building or structure served by the side wall horizontalvented gas fueled equipment. It shall be the responsibility of theproperty owner to secure the services of qualified licensed profes-sionals for the installation of hard wired carbon monoxide detec-tors

a. In the event that the side wall horizontally vented gas fueledequipment is installed in a crawl space or an attic, the hardwired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can notbe met at the time of completion of installation, the owner shallhave a period of thirty (30) days to comply with the aboverequirements; provided, however, that during said thirty (30)day period, a battery operated carbon monoxide detector withan alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbonmonoxide detector as required in accordance with the above pro-visions shall comply with NFPA 720 and be ANSI/UL 2034 listedand IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be perma-nently mounted to the exterior of the building at a minimum heightof eight (8) feet above grade directly in line with the exhaust ventterminal for the horizontally vented gas fueled heating applianceor equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEPCLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wallhorizontally vented gas fueled equipment shall not approve theinstallation unless, upon inspection, the inspector observes car-bon monoxide detectors and signage installed in accordance withthe provisions of 248 CMR 5.08(2)(a)1 through 4.

Table 1: Unit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an Upflow Configuration)

ApplicationTop Front Rear Left Side Right Side Flue Floor/

Bottom Closet Alcove Attic Line ContactIn. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm)

Upflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible Yes Yes Yes No

Downflow B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) 1 (25.4)1

1. Special floor base or air conditioning coil required for use on combustible floor.

Yes Yes Yes No

Horizontal B-Vent 1 (2.5) 1 (2.5) 0 (0.0) 0 (0.0) 0 (0.0) 1 (2.5) Combustible No Yes Yes Yes2

2. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building joists, studs or framing.

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SECTION II: DUCTWORKDUCTWORK GENERAL INFORMATIONThe duct system’s design and installation must:1. Handle an air volume appropriate for the served space and within

the operating parameters of the furnace specifications.

2. Be installed in accordance of National Fire Protection Association asoutlined in NFPA standard 90B (latest editions) or applicablenational, provincial, state, and local fire and safety codes.

3. Create a closed duct system. For residential and Non-HUD ModularHome installations, when a furnace is installed so that the supplyducts carry air circulated by the furnace to areas outside the spacecontaining the furnace, the return air shall also be handled by aduct(s) sealed to the furnace casing and terminating outside thespace containing the furnace.

4. Complete a path for heated or cooled air to circulate through the airconditioning and heating equipment and to and from the conditionedspace.

When the furnace is used with a cooling coil, the coil must be installedparallel with, or in the supply air side of the furnace to avoid condensa-tion in the primary heat exchanger. When a parallel flow arrangement isused, dampers or other means used to control airflow must be ade-quate to prevent chilled air from entering the furnace. If manually oper-ated, the damper must be equipped with means to prevent the furnaceor the air conditioner from operating unless the damper is in full heat orcool position.

When replacing an existing furnace, if the existing plenum is not thesame size as the new furnace then the existing plenum must beremoved and a new plenum installed that is the proper size for the newfurnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flowmay cause the limit controls not to operate as designed, or the limit con-trols may not operate at all.

The duct system is a very important part of the installation. If the ductsystem is improperly sized the furnace will not operate properly.The ducts attached to the furnace plenum, should be of sufficient sizeso that the furnace operates at the specified external static pressureand within the air temperature rise specified on the nameplate.

If a matching cooling coil is used, it may be placed directly on the fur-nace outlet and sealed to prevent leakage. If thermoplastic evaporator‘A’ coil drain pans are to be installed in the upflow/horizontal configura-tion, then extra 2” minimum spacing may be needed to ensure againstdrain pan distortion.

DUCT FLANGESFour flanges are provided to attach ductwork to the furnace. Theseflanges are rotated down for shipment. In order to use the flanges,remove the screw holding an individual flange, rotate the flange so it isin the upward position and reinstall the screw then repeat this for all 4flanges.

If the flanges are not used, they should remain in the rotated down posi-tion as shipped.

DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION - UPFLOW/HORIZONTAL

Attach the supply plenum to the furnace outlet. The use ofan approved flexible duct connector is recommended on allinstallations. This connection should be sealed to preventair leakage. The sheet metal should be crosshatched toeliminate any popping of the sheet metal when the indoorfan is energized.

FLOOR BASE AND DUCTWORK INSTALLATION - DOWNFLOW

Installations on combustible material or directly on anyfloors must use a combustible floor base shown in Figure 2.Follow the instructions supplied with the combustible floorbase accessory. This combustible floor base can bereplaced with a matching cooling coil, properly sealed toprevent leaks. Follow the instructions supplied with thecooling coil cabinet for installing the cabinet to the duct con-nector. Plug intake and vent pipe holes in bottom panel andmove grommet to desired vent side exit.

Downflow Air Conditioning Coil CabinetThe furnace should be installed with coil cabinet part number specifi-cally intended for downflow application. If a matching cooling coil isused, it may be placed directly on the furnace outlet and sealed to pre-vent leakage. For details of the coil cabinet dimensions and installationrequirements, refer to the installation instructions supplied with the coilcabinet.

Attach the air conditioning coil cabinet to the duct connector, and thenposition the furnace on top of the coil cabinet. The connection to the fur-nace, air conditioning coil cabinet, duct connector, and supply air ductmust be sealed to prevent air leakage.

CAUTIONThe cooling coil must be installed in the supply air duct, downstreamof the furnace. Cooled air may not be passed over the heatexchanger.

IMPORTANTThe minimum plenum height is 12” (30.5 cm). The furnace will notoperate properly on a shorter plenum height. The minimum recom-mended rectangular duct height is 4 inches (10 cm) attached to theplenum.

WARNINGThe duct system must be properly sized to obtain the correct airflowfor the furnace size that is being installed.Refer to Table 6 or the furnace rating plate for the correct rise rangeand static pressures.If the ducts are undersized, the result will be high duct static pres-sures and/or high temperature rises which can result in a heatexchanger OVERHEATING CONDITION. This condition can result inpremature heat exchanger failure, which can result in personal injury,property damage, or death.

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FIGURE 1: Duct Attachment

Factoryinstalled

For duct attachment,if needed.

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DOWNFLOW DUCT CONNECTORSAll downflow installations must use a suitable duct connector approvedby the furnace manufacturer for use with this furnace. The duct connec-tors are designed to be connected to the rectangular duct under thefloor and sealed. Refer to the instructions supplied with the duct con-nector for proper installation.

RESIDENTIAL AND MODULAR HOME UPFLOW RETURN PLENUM CONNECTIONReturn air may enter the furnace through the side(s) or bottom depend-ing on the type of application. Return air may not be connected into therear panel of the unit.

BOTTOM RETURN AND ATTIC INSTALLATIONSBottom return applications normally pull return air through a base plat-form or return air plenum. Be sure the return platform structure or returnair plenum is suitable to support the weight of the furnace.

The internal bottom panel must be removed for this application.

Attic installations must meet all minimum clearances to combustiblesand have floor support with required service accessibility.

HORIZONTAL APPLICATION

ATTIC INSTALLATION

This appliance is certified for line contact when the furnace is installedin the horizontal left or right position. The line contact is only permissiblebetween lines that are formed by the intersection of the top and twosides of the furnace and the building joists, studs or framing. This linemay be in contact with combustible material. Refer to Figure 4.

When moving or handling this furnace prior to installation, always leavethe doors on the furnace to provide support and to prevent damage orwarping of the cabinet. When lifting the furnace, support the ends of thefurnace rather than lifting by the cabinet flanges at the return air open-ings (bottom or sides) or supply air opening.

It is acceptable to use the primary heat exchanger tubes as a liftingpoint provided that the tubes are lifted at the front of the heat exchang-ers where attached to the vestibule panel. Do not use the top returnbend of the heat exchangers as lifting points as the tubes may shift outof position or their location brackets/baffles.

FIGURE 2: Combustible Floor Base Accessory

FIGURE 3: Horizontal Application (Typical)

FURNACE

WARM AIR PLENUMWITH 1” FLANGES

FIBERGLASSINSULATION

FIBERGLASS TAPEUNDER FLANGE

COMBUSTIBLE FLOORBASE ACCESSORY

IMPORTANTThis furnace may be installed in a horizontal position on either side asshown above. It must not be installed on its back.

FIGURE 4: Typical Attic Installation

WARNINGWhen a furnace is installed in an attic or other insulated space, keepall insulating materials at least 12 inches (30.5 cm) away from furnaceand burner combustion air openings.

IMPORTANTDuring installation, doors must remain on the furnace whenmoving or lifting.

30” Minimum Work Area

ReturnAir

SupplyAir

Vent Pipe(Maintain requiredclearances to combustiblematerials)

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SUSPENDED FURNACE / CRAWL SPACE INSTALLATIONThe furnace can be hung from floor joists or installed on suitable blocksor pads. Blocks or pad installations shall provide adequate height toensure that the unit will not be subject to water damage.

Units may also be suspended from rafters or floor joists using rods, pipeangle supports or straps. In all cases, the furnace should be supportedwith rods, straps, or angle supports at three locations to properly sup-port the furnace. Place one support at the supply end of the furnace,one support located approximately in the center of the furnace near theblower shelf, and the third support should be at the return end of the fur-nace. Maintain a 6” minimum clearance between the front of the fur-nace and the support rods or straps.

All six suspension points must be level to ensure proper and quiet fur-nace operation. When suspending the furnace, use a secure platformconstructed of plywood or other building materials secured to the flooror ceiling joists. Refer to Figure 5 for details and additional information.

When moving or handling this furnace prior to installation, always leavethe doors on the furnace to provide support and to prevent damage orwarping of the cabinet. When lifting the furnace, support the ends of thefurnace rather than lifting by the cabinet flanges at the return air open-ings (bottom or sides) or supply air opening.

It is acceptable to use the primary heat exchanger tubes as a liftingpoint provided that the tubes are lifted at the front of the heat exchang-ers where attached to the vestibule panel. Do not use the top returnbend of the heat exchangers as lifting points as the tubes may shift outof position or their location brackets/baffles.

DOWNFLOW APPLICATIONTo apply the furnace in a downflow position, it will be necessary torotate the vent blower 90° left or right so that the vent pipe passesthrough the side of the furnace casing rather than the end. See Figure 6.

COIL INSTALLATION

COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES COILS

FURNACE ASSEMBLY - MC & FC SERIES COILSThese coils are factory shipped for installation in either upflow or down-flow applications with no conversion.

Position the coil casing over or under the furnace opening as shown inFigure 7 after configuring coil flanges as required see “Coil Flange” sec-tion below.

COIL FLANGE INSTALLATIONThe coils include removable flanges to allow proper fit up with furnaceshaving various inlet and outlet flange configurations. The two flangesare attached to the top of the coil in the factory during production. Forproper configuration of flanges refer to Figure 8.

FIGURE 5: Typical Suspended Furnace / Crawl Space Installation

IMPORTANTDuring installation, doors must remain on the furnace whenmoving or lifting.

SupportRod

SupportAngle (x3)

Maintain 6” minimumclearance between supportrods and front of furnace

FIGURE 6: Downflow Venting

IMPORTANTOn all installations without a coil, a removable access panel is recom-mended in the outlet duct such that smoke or reflected light would beobservable inside the casing to indicate the presence of leaks in theheat exchanger. This access cover shall be attached in such a man-ner as to prevent leaks.

FIGURE 7: Vertical Applications (Typical)

LEFT SIDE VENT RIGHT SIDE VENT

Rotate ventblower 90°either way

UPFLOW DOWNFLOW

Fu

rna

ce

Fu

rna

ce

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FURNACE ASSEMBLY - MC SERIES COILS ONLYMC coils are supplied ready to be installed in a horizontal position. Ahorizontal pan is factory installed. MC coils should be installed in all hor-izontal applications with the horizontal drain pan side down.

For horizontal left hand applications no conversion is required to an MCcoil when used with a downflow/horizontal furnace. A mounting plate,supplied with every coil should always be installed on the side desig-nated as top side. See Figures 9 & 10.

FURNACE ASSEMBLY - PC SERIES COILSThese upflow coils are designed for installation on top of upflow fur-naces only.

If the coil is used with a furnace of a different size, use a 45° transitionto allow proper air distribution through the coil.

1. Position the coil casing over the furnace opening as shown in Figure11.

2. Place the ductwork over the coil casing flange and secure.

3. Check for air leakage between the furnace and coil casing and sealappropriately.

Dimension “C” should be at least 2/3 of dimension “D”. See Figure 11.

CRITICAL COIL PROJECTIONThe coil assembly must be located in the duct such that a minimum dis-tance is maintained between the top of the coil and the top of the duct.Refer to Table 2.

COIL / FURNACE ASSEMBLY - HC SERIES COILSThese coils are supplied ready to be installed in a right hand position ora left hand position. When used in conjunction with a horizontal furnace(blow through) application, the coil should be oriented with the openingof the “A” coil closest to the furnace. See Figure 12.

FIGURE 8: Coil Flange

FIGURE 9: Horizontal Right Application (Typical)

FIGURE 10: Horizontal Left Application

CAUTIONDo not drill any holes or drive any screws into the front duct flange onthe coil in order to prevent damaging coil tubing. See Figure 11.

ALTERNATEFLANGE LOCATION(Used for downflow orhorizontal leftinstallations)

FACTORYFLANGE

LOCATION(Used for upflow

or horizontalright installations)

Furnace

Mounting Plate

Furnace

Mounting Plate

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FIGURE 11: PC Series Upflow Coil Installation

Table 2: Coil Projection Dimensions - PC Series Coils

COIL SIZE DIMENSION “C” INCHPC18 3-1/2

PC24 4-1/2

PC30, PC32, PC35 4-1/2

PC42, PC43, PC36, PC37 5-1/2

PC48 6-1/2

PC60 9

NOTICEEach coil is shipped with an external tie plate that should be used tosecure the coil to the furnace. It should be installed on the back sideof the coil using the dimpled pilot holes. See Figure 12.

FIGURE 12: Horizontal Left or Right application (Right Shown)

FlexibleDuct Collar

Do not drillor Screwthis flange

FieldFabricatedDuctwork

UpflowCoil

UpflowFurnace

SecondaryDrain

PrimaryDrain

D

C(Min)

AlternateDrain Location

Use tie platesupplied with coil

Air flow

Gas Furnace

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SECTION III: FILTERSFILTER INSTALLATION

All applications require the use of a field installed filter. All filters andmounting provision must be field supplied.

Filters must be installed external to the furnace cabinet. DO NOTattempt to install filters inside the furnace.

1. Air velocity through throwaway type filters may not exceed 300 feet per minute (91.4 m/min). All velocities over this require the use of high velocity filters.

2. Do not exceed 1800 CFM using a single side return and a 16x25 filter. For CFM greater than 1800, you may use two side returns or one side and the bottom or one side return with a transition to allow use of a 20x25 filter.

SIDE RETURNLocate the “L” shaped corner locators. These indicate the size of the cut-out to be made in the furnace side panel. Refer to Figure 14.

Install the side filter rack following the instructions provided with thataccessory. If a filter(s) is provided at another location in the return air

system, the ductwork may be directly attached to the furnace sidepanel.

HORIZONTAL FILTERS

Any branch duct (rectangular or round duct) attached to the plenummust attach to the vertical plenum before the filter. The use of strapsand / or supports is required to support the weight of the external filterbox.

FIGURE 13: Dimensions

LEFT SIDE RIGHT SIDE

.5”

.5”

RETURN END

B

24.25”

29.5”(For Cladded door add appoximately an additional .75”)

28.5”

ElectricalEntry

Gas PipeEntry

ThermostatWiring

FRONT

14”

1”1.5”

23”

SUPPLY END

C

24.38”

20”.5”

B

Gas PipeEntry

ThermostatWiring

33”

A

.5”

ElectricalEntry

Vent ConnectionOutlet

VentConnectionOutlet

4” Diameter

OutletVent Connection

Table 3: Cabinet and Duct Dimensions

BTUH (kW)Input

NominalCFM (m3/min)

CabinetSize

Cabinet Dimensions (Inches) ApproximateOperating Weights

A A (cm) B B (cm) C C (cm) Lbs60 (17.6) 1200 (34.0) A 14 1/2 36.8 13 1/2 34.3 10.3 26.2 94

80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 1/2 41.9 11.8 29.9 103

80 (23.4) 1600 (45.3) C 21 53.3 20 50.8 13.6 34.5 114

100 (29.3) 1600 (45.3) C 21 53.3 20 50.8 13.6 34.5 118

100 (29.3) 2000 (56.6) C 21 53.3 20 50.8 13.6 34.5 122

120 (35.1) 2000 (56.6) C 21 53.3 20 50.8 15.8 40.1 129

CAUTIONAll filters and mounting provision must be field supplied. All installa-tions must have a filter installed.

Table 4: Recommended Filter Sizes (High Velocity 600 FPM)

CFM(m³/min)

CabinetSize

Side(in)

Bottom(in)

1200 (34.0) A 16 x 25 14 x 25

1200 (34.0) B 16 x 25 16 x 25

1600 (45.3) C 16 x 25 20 x 25

2000 (56.6) C (2) 16 x 25 20 x 25

!

FIGURE 14: Side Return Cutout Markings

IMPORTANTSome accessories such as electronic air cleaners and pleated mediamay require a larger side opening. Follow the instructions suppliedwith that accessory for side opening requirements. Do not cut theopening larger than the dimensions shown in Figure 13.

CAUTIONIn horizontal furnace arrangement, the filter must be located a mini-mum of 12” from the return air inlet of furnace.

Front ofFurnace

CornerMarkings

Side ofFurnace

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DOWNFLOW FILTERS

Downflow furnaces typically are installed with the filters located abovethe furnace, extending into the return air plenum or duct. Any branchduct (rectangular or round duct) attached to the plenum must attach tothe vertical plenum above the filter height.

Filter(s) may be located in the duct system external to the furnace usingan external duct filter box attached to the furnace plenum or at the endof the duct in a return filter grille(s). The use of straps and/or supports isrequired to support the weight of the external filter box.

SECTION IV: GAS PIPINGGAS SAFETY

GAS PIPING INSTALLATIONProperly sized wrought iron, approved flexible or steel pipe must beused when making gas connections to the unit. If local codes allow theuse of a flexible gas appliance connection, always use a new listed con-nector. Do not use a connector that has previously serviced another gasappliance.

Some utility companies or local codes require pipe sizes larger than theminimum sizes listed in these instructions and in the codes. The furnacerating plate and the instructions in this section specify the type of gasapproved for this furnace - only use those approved gases. The instal-lation of a drip leg and ground union is required. Refer to Figure 16.

The furnace must be isolated from the gas supply piping system byclosing its individual external manual shutoff valve during any pressuretesting of the gas supply piping system at pressures equal to or lessthan 1/2 psig (3.5 kPa).

Gas piping may be connected from either side of the furnace using anyof the gas pipe entry on both sides of the furnace. Refer to Figure 13.

GAS CONVERSION FOR PROPANE (LP)This furnace is constructed at the factory for natural gas-fired operation,but may be converted to operate on propane (LP) gas by using a fac-tory-supplied LP conversion kit. Follow the instructions supplied withthe LP kit.

CAUTIONIn downflow furnace arrangement, the filter must be located a mini-mum of 36” from the return air inlet of furnace.

DANGERAn overpressure protection device, such as a pressure regulator,must be installed in the gas piping system upstream of the furnaceand must act to limit the downstream pressure to the gas valve so itdoes not exceed 0.5 PSI (14" w.c. (3.48 kPa). Pressures exceeding0.5 PSI (14” w.c. (3.48 kPa) at the gas valve will cause damage to thegas valve, resulting in a fire or explosion or cause damage to the fur-nace or some of its components that will result in property damageand loss of life.

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!

IMPORTANTPlan your gas supply before determining the correct gas pipe entry.Use 90-degree service elbow(s), or short nipples and conventional90-degree elbow(s) to enter through the cabinet access holes.

FIGURE 15: Gas Valve

InletPressureTap

OutletPressureTap

On/OffSwitch

MainRegulatorAdjustment

FIGURE 16: Gas Piping

UpflowConfiguration

DownflowConfiguration

HorizontalConfiguration

ExternalManualShut-offValve

ExternalManualShut-offValve

ExternalManualShut-offValve

To GasSupply

To GasSupply

To GasSupply

To GasSupply

To GasSupply

To GasSupply

DripLeg

DripLeg Drip

Leg

DripLeg

Drip Leg

Drip Leg

GasValve

GasPipe

GasValve

Gas Pipe

GasValve

GroundUnion

GroundUnion

GroundUnion

GroundUnion

GroundUnion

NOTE: Ground Union maybe installed inside or outside unit.

IMPORTANTAn accessible manual shutoff valve must be installed upstream of thefurnace gas controls and within 6 feet (1.8 m) of the furnace.

CAUTIONThe gas valve body is a very thin casting that cannot take any exter-nal pressure. Never apply a pipe wrench to the body of the gas valvewhen installing piping. A wrench must be placed on the octagon hublocated on the gas inlet side of the valve. Placing a wrench to thebody of the gas valve will damage the valve causing improper opera-tion and/or the valve to leak.

! WARNING

LoNOx furnaces requiring propane (LP) gas must have the LoNOxscreens removed prior to installation and operation. See propaneinstructions.

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HIGH ALTITUDE NATURAL GAS ORIFICE CONVERSIONThe National Fuel Gas Code requires that gas appliances installedabove 2,000 feet elevation have their inputs de-rated by 4% per 1,000feet above sea level. The modulating furnaces automatically de-rate foraltitude by measuring the inducer blower pressure and using that todetermine if there is adequate air to support good combustion. If thereis not enough combustion air to properly support 100% of the furnacenameplate input rate, the control will reduce the input to the point thatthere will be good combustion.

The factory gas orifice sizes are based on a gas heating value of1030 BTU/Cu.ft., so if your gas value is significantly higher orlower than that, it may be necessary to change to smaller or largergas orifices.The chart below shows recommended gas orifice sizes to use at vari-ous altitudes and at various de-ration levels. To use the chart, followthese instructions:

1. Clock the gas meter and calculate the actual input rate using yourlocal gas heating value. See "CALCULATING THE FURNACEINPUT (NATURAL GAS)" in this manual.

2. Divide that input rate by the input rate shown on the furnace ratingplate to get the actual de-ration percent.

3. Read down the left-hand “Actual Rate” column to find the closestnumber to your actual de-ration percent.

4. Read across that row to the column for the elevation at your location.The number listed there is the orifice size that is proper for your unit.

Example – You have a 100,000 BTU/H furnace installed at an elevationof 6,000 feet. You clock the gas meter and find that the furnace is actu-ally fired at 64,000 BTU/H. Divide 64,000 by 100,000, which gives 0.64(64%). The closest number to 64% in the left-hand “Actual Rate” col-umn is 65. Read across that row to the column for 6,000 feet elevation,which shows “#43”. You should change from the factory #45 orifices tolarger #43 orifices, which will bring the input rate back up to approxi-mately 76,000 BTU/H, which is what it should be for that furnace at6,000 feet.

Table 5: High Altitude Orifices

Actual Rate (percent of nameplate)

Elevation in Feet Above Sea Level 4,000 5,000 6,000 7,000 8,000 9,000 10,000 84% 80% 76% 72% 68% 64% 60%

Orifice Drill Size 100 48 49 49 50 51 51 52 95 47 48 49 50 50 50 51 90 46 47 48 49 49 49 50 85 45 46 47 48 49 49 50 80 45 45 46 47 48 48 49 75 44 45 45 45 47 47 49 70 43 44 44 45 45 45 48 65 42 43 43 44 45 45 47 60 41 42 42 43 44 45 46 55 40 41 41 32 43 43 44 50 39 40 40 40 43 42 42

DANGERPROPANE KITSIt is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-pane (LP) gas. Do not use this furnace with butane gas.Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heatexchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.Propane (LP) conversions are required in order for the appliance to satisfactory meet the application.An authorized distributor or dealer must make all gas conversions.In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames, caus-ing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/ordeath.

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SECTION V: ELECTRICAL POWERELECTRICAL POWER CONNECTIONSField wiring to the unit must be grounded. Electric wires that are fieldinstalled shall conform to the temperature limitation for 63°F (35°C) risewire when installed in accordance with instructions. Refer to Table 6 inthese instructions for specific furnace electrical data.

* If chimney kit S1-1CK0605 is installed, minimum inputs and outputs are 65% of maximum, not 50%. See Chimney kit instructions and label for more details.Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.The furnace shall be installed so that the electrical components are protected from water.

SUPPLY VOLTAGE CONNECTIONS

1. Provide a power supply separate from all other circuits. Install over-current protection and disconnect switch per local/national electricalcodes. The switch should be close to the unit for convenience in ser-vicing. With the disconnect or fused switch in the OFF position,check all wiring against the unit wiring label. Refer to the wiring dia-gram in this instruction.

2. Remove the screws retaining the wiring box cover. Route the powerwiring through the opening in the unit into the junction box with aconduit connector or other proper connection. In the junction boxthere will be 3 wires, a Black Wire, a White Wire. Connect the powersupply as shown on the unit-wiring label on the inside of the blowercompartment door or the wiring schematic in this section. The blackfurnace lead must be connected to the L1 (hot) wire from the powersupply. The white furnace screw must be connected to neutral. Con-nect the power supply ground to the green screw (equipmentground) An alternate wiring method is to use a field provided 2” (5.1cm) x 4” (10.2 cm) box and cover on the outside of the furnace.Route the furnace leads into the box using a protective bushingwhere the wires pass through the furnace panel. After making thewiring connections replace the wiring box cover and screws. Refer toFigure 17.

3. The furnace's control system requires correct polarity of the powersupply and a proper ground connection. Refer to Figure 17.

CAUTIONUse copper conductors only.

!

Table 6: Ratings & Physical / Electrical Data

InputMax/Min *

OutputMax/Min *

NominalAirflow

Air Temp. RiseMax Input

Air Temp. RiseMin Input

MBH kW MBH kW CFM m3/min °F °C °F °C

60/30 17.6/8.8 47/24 13.8/7.0 1200 34.0 30-60 17-33 20-50 11-2880/40 23.5/11.8 62/32 18.2/9.4 1200 34.0 40-70 22-39 20-50 11-2880/40 23.5/11.8 62/32 18.2/9.4 1600 45.3 35-65 19-36 20-50 11-28100/50 29.3/14.7 78/40 22.8/11.7 1600 45.3 35-65 19-36 20-50 11-28100/50 29.3/14.7 78/40 22.8/11.7 2000 56.6 35-65 19-36 20-50 11-28120/60 33.7/16.9 95/48 27.8/14.1 2000 56.6 45-75 25-42 25-55 13-31

Max. Outlet Air Temp Blower BlowerWheel size

AFUE%

Max Over-Current Protect

Total UnitAmps

Min. wire Size (awg) @ 75 ft one way°F °C HP Amps

190 88 1/2 4.8 11 x 8 80.0 15 7.0 14190 88 1/2 4.8 11 x 8 80.0 15 7.5 14190 88 3/4 7.5 11 x 10 80.0 15 10.0 14190 88 3/4 7.5 11 x 10 80.0 15 10.0 14190 88 1 14.5 11 x 11 80.0 20 12.0 12190 88 1 14.5 11 x 11 80.0 20 12.0 12

FIGURE 17: Electrical Wiring

Electrical Entry

JunctionBox

L1-Hot

Neutral

Connect groundlead to screw

BLK

WHT

IMPORTANTThe power connection leads and wiring box may be relocated to theleft side of the furnace. Remove the screws and cut wire tie holdingexcess wiring. Reposition on the left side of the furnace and fastenusing holes provided.

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CONTROL WIRINGThis furnace can be connected to the wall thermostat and outdoor A/Cor heat pump using either conventional low voltage (24 VAC) thermo-stat wiring OR using four-wire digital communications wiring. To useconventional low voltage wiring, see the section below entitled “Con-ventional Low Voltage Control Wiring”. To use four-wire communica-tions control wiring, see the section below entitled “Control Wiring usingCommunicating Controls”.

The Communicating System consists of several intelligent communicat-ing components including the Communicating Thermostat Control(touch-screen wall thermostat), modulating variable speed furnace, airconditioner (15 and 18 SEER premium air conditioners) or heat pump(13, 15 and 18 SEER premium heat pumps), which continually commu-nicate with each other via a four-wire connection called the C-B bus.Commands, operating conditions, and other data are passed continu-ally between components over the C-B bus. See Figure 19. The resultis a new level of comfort, versatility, and simplicity.

In order to use this furnace in full communications (COMM) mode, itMUST be installed with the matching touch-screen CommunicatingControl (wall thermostat) and an outdoor air conditioner or heat pumpwith a fully communicating control.

This furnace may also be used along with the Communicating Thermo-stat Control and a non-communicating outdoor air conditioner throughthe addition of a communicating Outdoor Aux Control board to the out-door unit. This system allows full communication between the furnaceand thermostat and limited communication to the outdoor unit. See Fig-ure 20.

This furnace may also be used along with the Communicating Thermo-stat Control and a non-communicating outdoor air conditioner or heatpump using COMM between the furnace and thermostat and conven-tional 24V wiring to the outdoor unit. This system allows full communi-cation between the furnace and thermostat but no digitalcommunication with the outdoor unit.

FIGURE 18: Furnace Control Board – Communications Connections

Diagnostic Light

CFM Light

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CONTROL WIRING USING COMMUNICATING CONTROLSUse the wiring diagram below to connect the furnace control, Communi-cating Control (wall thermostat) and communicating outdoor unit. Besure that all of the “A” terminals are connected together, all of the “B”terminals are connected together, all of the “C” terminals are connectedtogether and all of the “R” terminals are connected together. See Figure19. When using a fully communicating system, the large screw termi-nals (C, G, R, etc.) on the furnace control are not used. The four smallscrew terminals in the terminal block on the end of the furnace controlshould be used.

When connecting the Communicating Control (wall thermostat) and fur-nace control to a non-communicating outdoor A/C or heat pump, usethe wiring diagram in Figure 20. The thermostat and furnace will be con-nected exactly as shown above, but the conventional 24 volt R, C andY/Y2 terminals will be used to control the outdoor unit.

CONVENTIONAL LOW VOLTAGE CONTROL WIRING CONNECTIONSInstall the field-supplied thermostat by following the instructions thatcome with the thermostat. With the thermostat set in the OFF positionand the main electrical source disconnected, connect the thermostatwiring from the wiring connections on the thermostat to the terminalboard on the ignition module, as shown in Figures 21-26, ThermostatCharts. Electronic thermostats may require the common wire to be con-nected as shown in Figures 22 - 26. Apply strain relief to thermostatwires passing through cabinet.

The 24-volt, 40 VA transformer is sized for the furnace componentsonly, and should not be connected to power auxiliary devices such ashumidifiers, air cleaners, etc. The transformer may provide power for anair conditioning unit contactor.

AIR CONDITIONER CONNECTIONSThis furnace may be used with single-stage or two-stage air condition-ing units.

For Single-Stage A/C - Connect the low voltage wiring as shown inFigure 21, Thermostat Chart.

For Two-Stage A/C - Use a two-stage thermostat, connect the low volt-age wiring as shown in Figure 22, Thermostat Chart.

For Two-Stage A/C using a Single-Stage Thermostat - connect thelow voltage wiring as shown in Figure 23, Thermostat Chart.

This furnace control board can control a two-stage A/C using only a sin-gle-stage thermostat. In this case, the furnace control switches betweenhigh cool and low cool based on the calculated cooling load.

FIGURE 19: Modulating Furnace with Communicating AC or HP

FIGURE 20: Modulating Furnace with Communicating Thermostat and Non-communicating AC

A+

R

C

B-

A+

R

C

B-

A+

R

GND

B-

LOCOMP

HICOMP

O

DHUM

Y1

Y/Y2

W

R

G

C

Touch ScreenCommunicating control

Modulating FurnaceCommunicating control

Air Conditioner/Heat PumpCommunicating control

A+

R

C

B-

A+

R

B-

LOCOMP

HICOMP

O

DHUM

Y1

Y/Y2

W

R

G

C

Touch ScreenCommunicating control

Modulating FurnaceCommunicating control

Non-Air Conditioner

Communicating

Y

Y2

R

C

C

IMPORTANTSet the heat anticipator in the room thermostat to 0.1 amps. Setting itlower will cause short cycles. Setting it higher will cause the roomtemperature to exceed the set points.

IMPORTANTSome electronic thermostats do not have adjustable heat anticipa-tors. They should be set to six cycles per hour. Follow the thermostatmanufacturer's instructions.

14 Johnson Controls Unitary Products

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For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com inthe Product Catalog Section.

FIGURE 21: Thermostat Chart - Single Stage Air Conditioner – Variable Speed or PSC Modulating Furnace

HM1Humidistat

YFull Stage Compressor

GFan

*PP11C70224

THERMOSTAT

RH24 – Volt Hot(Heat XFMR)

RC24 – Volt Hot(Cool XFMR)

WFull Stage Heat

Clipping Jumper W914 forelectric heat on thermostat

is not necessary

C24 – Volt Common

YCompressor

SINGLE STAGEAIR CONDITIONER

YCompressor Contactor

SINGLE STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

1

1

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

Part Number:S1-2HU16700124

2

External Humidistat(Optional)

Open on Humidity Rise

2

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FIGURE 22: Thermostat Chart - Two Stage Air Conditioner – Variable Speed or PSC Modulating Furnace

C24 – Volt Common

Y1First Stage Compressor

Y2Second StageCompressor

GFan

*PP32U70124

THERMOSTAT

AUXAuxiliary Heat

R24 – Volt Hot(Heat XFMR)

R24 – Volt Hot(Cool XFMR)

C24 – Volt Common

Y1First Stage Compressor

Y2Second StageCompressor

GFan

*DN22U00124

THERMOSTAT

W2Second Stage Heat

R24 – Volt Hot(Heat XFMR)

R24 – Volt Hot(Cool XFMR)

E/W1Emergency Heat

E/W1First Stage Heat

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

Y2Second StageCompressor

Connection of the “C”terminal, 24-Volt commonis optional when used with

batteriesThermostat Installer Setup0170-System Type-mustbe set to 8-2 Heat/2 CoolMultistage Conventional

Connection of the “C”terminal, 24-volt commonis optional when used with

batteriesThermostat Installer Setup

1-System Type-mustbe set to 6-2 Heat/2 CoolMultistage Conventional

Thermostat Installer Setup15-Compressor Protection

-must be set to 5

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

1

1

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

External Humidistat(Optional)

Open on Humidity Rise

2

Part Number:S1-2HU16700124

2

16 Johnson Controls Unitary Products

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FIGURE 23: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed or PSC Modulating Furnace

HM1Humidistat

YFull Stage Compressor

GFan

*PP11C70224

THERMOSTAT

RH24 – Volt Hot(Heat XFMR)

RC24 – Volt Hot(Cool XFMR)

WFull Stage Heat

Clipping Jumper W914 forelectric heat on thermostat

is not necessary

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

1

1

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

TWO STAGEAIR

CONDITIONER

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

Y2Second StageCompressor

External Humidistat(Optional)

Open on Humidity Rise

2

Part Number:S1-2HU16700124

2

Johnson Controls Unitary Products 17

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FIGURE 24: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

OReversing Valve

Energized in Cool

LMalfunction Light

GFan

*DP32H70124

THERMOSTAT

W1Second Stage Aux. Heat

EEmergency Heat

W2Third Stage HeatN/A

*BP21H50124*BN21H00124*DP21H40124*DN21H00124

THERMOSTAT

N/A

*DN22U00124

THERMOSTAT

Part Numbers:SAP = Legacy

67297 = 031-01975

OReversing Valve

Energized in Cool

C24 – Volt Common

R24 – Volt Hot

W1/66(out)Heat

YCompressor

DEMAND DEFROSTCONTROL

X/LMalfunction Light

WAuxiliary Heat

SINGLE STAGEHEAT PUMP

1

1 Part Number:S1-2HU16700124

3

Y2Second Stage Compressor

Step 9 of ThermostatInstaller / Configuration

Menu must be set toPump OFF

Step 1 of ThermostatInstaller / Configuration

Menu must be set toHeat Pump 1

OD MODELS*HGD *HJR

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

2

2

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

External Humidistat(Optional)

Open on Humidity Rise

3

TP9CYP9CCP9CLP9C

*HJD*HGF*HJF

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FIGURE 25: Thermostat Chart - Single Stage Heat Pump – Variable Speed or PSC Modulating Furnace

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

OReversing Valve

Energized in Cool

LMalfunction Light

GFan

*DP32H70124

THERMOSTAT

W1Second Stage Aux. Heat

EEmergency Heat

W2Third Stage Heat

Step 1 of ThermostatInstaller / Configuration

Menu must be set toHeat Pump 1

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

OReversing Valve

Energized in Cool

LMalfunction Light

Y2Second

Stage Compressor

GFan

*BP21H50124*BN21H00124*DP21H40124*DN21H00124

THERMOSTAT

EEmergency Heat

W2Second Stage Heat

B/O Switch on Thermostatmust be in the O position

C24 – Volt Common

Y1First Stage Compressor

O/BReversing Valve

LMalfunction Light

Y2Second

Stage Compressor

GFan

*DN22U00124

THERMOSTAT

EEmergency Heat

AUXAuxiliary Heat

R24 – Volt Hot(Heat XFMR)

R24 – Volt Hot(Cool XFMR)

OReversing Valve

Energized in Cool

C24 – Volt Common

R24 – Volt Hot

W1 OUTFirst Stage Heat

W2 OUTSecond Stage Heat

Y2 OUTSecond

Stage Compressor

Y1Single

Stage Compressor

X/LMalfunction Light

Y2Second

Stage Compressor

WAuxiliary Heat

BSBonnet Sensor

BSGBonnet Sensor

YORKGUARD VICONTROL

SINGLE STAGEHEAT PUMP

Bonnet Sensor(Optional)

Change FFuel jumperon the heat pump control

to “ON”

1

H*3YMBYZB

OD MODELS

Y2Second

Stage Compressor

Thermostat Installer Setup1-System Type-must be set to 5 – 2 Heat/1 Heat PumpThermostat Installer Setup2-Changeover Valve-mustbe set to 0 – O/B terminal

Energized in Cooling

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

2

2

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

Change Hot Heat Pump jumper on the heat

pump control to “ON” if Hot Heat Pump

Operation is desired.

Part Number:S1-2HU16700124

3

External Humidistat(Optional)

Open on Humidity Rise

3

Part Numbers:SAP = Legacy

126768 = 031-0913718395 = 031-01996340512 = 031-09178

1

TP9CYP9CCP9CLP9C H*6

YZF

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FIGURE 26: Thermostat Chart - Two Stage Heat Pump – Variable Speed or PSC Modulating Furnace

OReversing Valve

Energized in Cool

C24 – Volt Common

R24 – Volt Hot

W1 OUTFirst Stage Heat

W2 OUTSecond Stage Heat

Y2 OUTSecond

Stage Compressor

Y1Single

Stage Compressor

X/LMalfunction Light

Y2Second

Stage Compressor

WAuxiliary Heat

BSBonnet Sensor

BSGBonnet Sensor

YORKGUARD VICONTROL

TWO STAGEHEAT PUMP

Bonnet Sensor(Optional)

Change FFuel jumperon the heat pump control

to “ON”

1

Part Numbers:SAP = Legacy

126768 = 031-0913718395 = 031-01996340512 = 031-09178

1

YZEOD MODELS

YZHH*5H*8

C24 – Volt Common

R24 – Volt Hot

Y1First Stage Compressor

OReversing Valve

Energized in Cool

LMalfunction Light

Y2Second

Stage Compressor

GFan

*DN22H00124*DP22U70124

THERMOSTAT

E/W1First Stage Aux. Heat

W2Second Stage Aux. Heat

C24 – Volt Common

YFirst Stage Compressor

O/BReversing Valve

LMalfunction Light

Y2Second

Stage Compressor

GFan

*PP32U70124

THERMOSTAT

EEmergency Heat

R24 – Volt Hot(Heat XFMR)

RC24 – Volt Hot(Cool XFMR)

AUXAuxiliary Heat

Step 1 of ThermostatInstaller/Configuration

Menu must be set to “HP2”Selection of GAS/ELEC

switch on thermostat not necessary

Thermostat Installer Setup0170-System Type-must be set to 12

3 Heat/2 Heat PumpThermostat Installer Setup0190-Changeover Valve-

must be set to 0O/B terminal

Energized in CoolingThermostat Installer Setup0200-Backup Heat Source-

must be set to 1Heat Pump Backup Heat

Source is Fossil FuelThermostat Installer Setup0210-External Fossil Fuel

Kit- must be set to 1Heat Pump Control

is Controlling Heat PumpBackup Heat

C24 – Volt Common

R24 – Volt Hot

Y1Single

Stage Compressor

MODULATINGFURNACE CONTROL

GFan

MODULATINGFURNACE

Y/Y2Second or Full

Stage Compressor

DHUMDehumidification-

Open on Humidity Rise

WModulating Heat

Part Numbers:SAP = Legacy

2

2

Move HUMIDISTATjumper to “YES”

if humidistat is to be used.

ID MODELS

LO COMPSingle Stage

Compressor (OUT)

OReversing Valve

Energized in Cool

HI COMPSecond Stage

Compressor (OUT)

Change Hot Heat Pump jumper on the heat

pump control to “ON” if Hot Heat Pump

Operation is desired.

External Humidistat(Optional)

Open on Humidity Rise

3

TPLC

YPLCCPLCLPLC

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ACCESSORY CONNECTIONSThe furnace control will allow power-switching control of various acces-sories.

ELECTRONIC AIR CLEANER CONNECTIONTwo 1/4” (0.64 cm) spade terminals (EAC and NEUTRAL) for electronicair cleaner connections are located on the control board. The terminalsprovide 115 VAC (1.0 amp maximum) during circulating blower opera-tion.

HUMIDIFIER CONNECTIONTwo 1/4” (0.64 cm) spade terminals (HUM and NEUTRAL) for humidi-fier connections are located on the control board. The terminals provide115 VAC (1.0 amp maximum) during heating system operation.

A mounting hole is provided on the control panel next to the furnacecontrol board for mounting a humidifier transformer if required.

HUMIDISTAT CONNECTIONFor better humidity control during cooling operation, an external humidi-stat may be used. When using a external humidistat, put the HUMIDI-STAT jumper in the “YES” position. Connect the low voltage wiring asshown in Figures 21-26, Thermostat Charts.

ZONING OPERATIONThis furnace may be used in zoning systems, using a separate after-market zoning control. For use in zoned systems, put the ZONE CON-TROL jumper on the furnace control board in the “YES” position.

If the Zone jumper is put in the “Yes” position, the heating load logicswitches to a special algorithm for multi-zone homes.

1. This algorithm operates at the “low demand” firing rate for 10 min-utes and then ramps to high fire within 20 minutes (30 minutes max-imum to get to 100% firing rate).

2. The special zoning algorithm does not have the Run 2 function, sothe burners will stop firing as soon as there is no call for heating.

HEAT PUMP OPERATIONThis furnace may be used in conjunction with a heat pump in dual fuelapplications. For heat pump applications, put the HEAT PUMP jumperon the furnace control board in the “YES” position. Connect the low volt-age wiring as shown in Figures 24-26, Thermostat Charts. If a two-stage heat pump is to be used, a two-stage thermostat is required.

If the Heat Pump jumper is in the “Yes” position, it indicates that there isa heat pump present and the furnace is used as a secondary heatsource. In addition, the “Yes” Heat Pump jumper allows the system toread the presence of the “O” terminal signal. In heat pump operation,the following special algorithm logic applies:

1. Supplemental Heating - When both a “W” signal and a “Y1” signalare present, the modulating firing rate will operate as normal, exceptthere will be no Run 2 function, so the burners will stop firing as soonas the “W” signal is removed.

2. Defrost Cycle - When both a “W” signal and a “Y2” signal are pres-ent, the modulating firing rate will operate at a constant 80% firingrate and there will be no Run 2 function, so the burners will stop fir-ing as soon as the “W” signal is removed.

3. Hot Heat Pump - The “hot” heat pump feature will work when thecontrol is wired to a 2-stage thermostat and a 2-stage heat pump.

4. Hot Heat Pump - The “hot” heat pump feature will not work when thecontrol is wired to a single-stage thermostat and a 2-stage heatpump.

TWINNINGThese furnaces are not to be twinned. If more than one furnace isneeded in an application, each furnace must have its own completeduct system and its own wall thermostat.

SECTION VI: VENT SYSTEMVENT CONNECTIONSFigure 27 shows the furnace as it is shipped from the factory. To con-vert to a horizontal or downflow position, remove the four screws thatsecure the inducer assembly and rotate 90° being careful not to dam-age the gasket. Reinstall screws. Remove cap from appropriate ventoutlet location on the cabinet cut insulation in cabinet to same size asthe hole provided and reinstall cap in the hole in the top panel.

CATEGORY 1 - 450 F. MAX. VENT TEMP.The venting system must be installed in accordance with Section 5.3,Air for Combustion and Ventilation, of the National Fuel Gas CodeZ223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSAB149.1, National Gas and Propane Codes (latest edition) or applicableprovisions of the local building code and these instructions.

The furnace shall be connected to a type B vent connector, andshall be connected to a type B vent only. The furnace shall not beconnected to a chimney flue serving a separate appliancedesigned to burn solid fuel. Single-wall vent pipe is not allowed.It is recommended that the appliance is installed in a location where thespace temperature is 32 °F (0°C) or higher. If the appliance is installedin a location where the ambient temperature is below 32 °F (0°C), thecombustion byproducts could condense causing damage to the appli-ance heat exchanger.

This appliance may be common vented with another gas appliance forresidential installations as allowed by the codes and standards listed inthese instructions.

VENTINGCategory I venting consists of vertically venting one or more appliancesin B-vent or B-vent connectors. Type B-vent system extends in a gen-eral vertical direction and does not contain offsets exceeding 45°. Avent system having not more than one 60° offset is permitted.

VENTING INTO AN EXISTING CHIMNEYThis furnace may not be vented directly into an unlined or clay tile-linedmasonry chimney. This furnace may be vented into a masonry chimneyif a double-wall metal chimney liner is used and the liner is properlysized according to the requirements of the National Fuel Gas Code or inCanada, the B-149 Installation Codes.

If this furnace is to be vented into a masonry lined chimney without adouble-wall chimney liner, chimney kit S1-1CK0605 must be used.Refer to the instructions with that kit for details.

IMPORTANTIn downflow applications, do not block the combustion air inlet. Thefurnace must be installed on a coil cabinet or subbase to allow com-bustion air to enter the burner compartment.

FIGURE 27: Combustion Air Inducer

COMBUSTION AIR INDUCER

90° 90°Mounting Screw(Remove)

Flue Transition(Do Not Remove)

Mounting Screw(Remove)

PressureSwitch

Pressure SwitchTube Routing

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FAN-ASSISTED COMBUSTION SYSTEMThis appliance is equipped with an integral mechanical means to drawproducts of combustion through the heat exchanger.

Ambient Combustion Air Supply This type installation will draw the air required for combustion fromwithin the space surrounding the appliance and from areas or roomsadjacent to the space surrounding the appliance. This may be fromwithin the space in a non-confined location or it may be brought into thefurnace area from outdoors through permanent openings or ducts. Asingle, properly sized pipe from the furnace vent connector to the out-doors must be provided. For upflow models combustion air is broughtinto the furnace through the unit top panel opening.

An unconfined space is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/hr (0.2928 kW) input rating for all of the appliances installed in thatarea.

Rooms communicating directly with the space containing the appli-ances are considered part of the unconfined space, if openings are fur-nished with openings or louvers.

A confined space is an area with less than 50 cu.ft (1.42 m3) per 1,000Btu/hr (0.2928 kW) input rating for all of the appliances installed in thatarea. The following must be considered to obtain proper air for combus-tion and ventilation in confined spaces.

Combustion Air Source From OutdoorsThe blocking effects of louvers, grilles and screens must be given con-sideration in calculating free area. If the free area of a specific louver orgrille is not known, refer to Table 7, to estimate free area.

* Do not use less than 1/4”(0.635 cm) mesh+ Free area of louvers and grille varies widely; the installer should follow

louver or grille manufacturer’s instructions.

Dampers, Louvers and Grilles (Canada Only)1. The free area of a supply air opening shall be calculated by subtract-

ing the blockage area of all fixed louvers grilles or screens from thegross area of the opening.

2. Apertures in a fixed louver, a grille, or screen shall have no dimen-sion smaller than 0.25” (0.64 cm).

3. A manually operated damper or manually adjustable louvers are notpermitted for use.

4. A automatically operated damper or automatically adjustable louversshall be interlocked so that the main burner cannot operate unlesseither the damper or the louver is in the fully open position.

FIGURE 28: Combustion Airflow Path Through The Furnace Casing to the Burner Compartment

WARNINGThis type of installation requires that the supply air to the appliance(s)be of a sufficient amount to support all of the appliance(s) in the area.Operation of a mechanical exhaust, such as an exhaust fan, kitchenventilation system, clothes dryer or fireplace may create conditionsrequiring special attention to avoid unsatisfactory operation of gasappliances. A venting problem or a lack of supply air will result in ahazardous condition, which can cause the appliance to soot and gen-erate dangerous levels of CARBON MONOXIDE, which can lead toserious injury, property damage and / or death.

COMBUSTION AIR

!

Table 7: Estimated Free Area

Wood or MetalLouvers or Grilles

Wood 20-25%*Metal 60-70% *

Screens+1/4” (0.635 cm)

mesh or larger 100%

WARNINGWhen a Category I furnace is removed or replaced, the original vent-ing system may no longer be correctly sized to properly vent theattached appliances.An improperly sized vent system can cause CARBON MONOXIDE tospill into the living space causing personal injury, and or death.

Table 8: Unconfined Space Minimum Area

BTUH Input RatingMinimum Free Area

Required for Each Opening

60,000 60 in2 (387 cm2)

80,000 80 in2 (516 cm2)

100,000 100 in2 (645 cm2)

120,000 120 in2 (742 cm2)

Table 9: Free Area

BTUH Input Rating

Minimum Free Area Required for Each Opening

Horizontal Duct (2,000 BTUH)

Vertical Duct or Opening to Outside

(4,000 BTUH)

Round Duct(4,000 BTUH)

60,000 30 in2 (193 cm2) 15 in2 (97 cm2) 5” (13 cm)

80,000 40 in2 (258 cm2) 20 in2 (129 cm2) 5” (13 cm)

100,000 50 in2 (322 cm2) 25 in2 (161 cm2) 6” (15 cm)

120,000 60 in2 (387 cm2) 30 in2 (193 cm2) 7” (18 cm)

EXAMPLE: Determining Free Area.Appliance 1 Appliance 2 Total Input100,000 + 30,000 = (130,000 4,000) = 32.5 Sq. In. VerticalAppliance 1 Appliance 2 Total Input100,000 + 30,000 = (130,000 2,000) = 65 Sq. In. Horizontal

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22 Johnson Controls Unitary Products

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Air Supply Openings and Ducts1. An opening may be used in lieu of a duct to provide the outside air

supply to an appliance unless otherwise permitted by the authorityhaving jurisdiction. The opening shall be located within 12” (30.5 cm)horizontally from, the burner level of the appliance. Refer to “COM-BUSTION AIR SOURCE FROM OUTDOORS and VENT AND SUP-PLY AIR SAFETY CHECK” in these instructions for additionalinformation and safety check procedure.

2. The duct shall be either metal, or a material meeting the class 1requirements of CAN4-S110 Standard for Air Ducts.

3. The duct shall be least the same cross-sectional area as the freearea of the air supply inlet opening to which it connects.

4. The duct shall terminate within 12 in (30.5 cm) above, and within 24in (61 cm) horizontally from, the burner level of the appliance havingthe largest input.

5. A square or rectangular shaped duct shall only be used when the

required free area of the supply opening is 9 in2 (58.06 cm2) orlarger. When a square or rectangular duct is used, its small dimen-sion shall not be less than 3 in (7.6 cm).

6. An air inlet supply from outdoors shall be equipped with a means toprevent the direct entry of rain and wind. Such means shall notreduce the required free area of the air supply opening.

7. An air supply inlet opening from the outdoors shall be located notless than 12” (30.5 cm) above the outside grade level.

Combustion Air Source from Outdoors1. Two permanent openings, one within 12 in (30.5 mm) of the top and

one within 12 in (30.5 mm) of bottom of the confined space, Two per-manent openings, shall communicate directly or by means of ductswith the outdoors, crawl spaces or attic spaces.

2. One permanent openings, commencing within 12 in (30.5 mm) of thetop of the enclosure shall be permitted where the equipment hasclearances of at least 1 in (2.54 cm) from the sides and back and 6 in(15.24 cm) from the front of the appliance. The opening shall com-municate directly with the outdoors and shall have a minimum freearea of:

a. 1 square in per 3000 Btu per hour (6.45 cm3 per 0.879 kW) of thetotal input rating of all equipment located in the enclosure.

b. Not less than the sum of all vent connectors in the confinedspace.

3. The duct shall be least the same cross-sectional area as the freearea of the air supply inlet opening to which it connects.

4. The blocking effects of louvers, grilles and screens must be givenconsideration in calculating free area. If the free area of a specificlouver or a grille is not known. Refer to Table 7 to estimate free area.

Ventilated Combustion AirThe ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in “AIR SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition). This type installation requires two properly sized pipes. One brings combustion air from a properly ventilated attic space or crawl space and a second pipe that extends from the furnace vent connection (top right of unit) to the exterior of the building.

Vent and Supply (Outside) Air Safety Check ProcedureFor Category I furnaces, vent installations shall be in accordance withParts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,and or Section 7 and Appendix B of the CSA B149.1, Natural Gas andPropane Installation Codes, the local building codes, furnace and ventmanufacture's instructions.

Multi-story or common venting systems are permitted and must beinstalled in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and / or the CSA B149.1, Natural Gas and Propane Installa-tion Codes, local codes, and the manufacture's instructions.

Vent connectors serving Category I furnaces shall not be connectedinto any portion of mechanical draft systems operating under positivepressure.

Horizontal portions of the venting system shall be supported to preventsagging using hangers or perforated straps and must slope upwardsnot less than 1/4” per foot (0.635 cm/m) from the furnace to the vent ter-minal.

It is recommended that you follow the venting safety procedure below.This procedure is designed to detect an inadequate ventilation systemthat can cause the appliances in the area to operate improperly causingunsafe levels of Carbon Monoxide or an unsafe condition to occur.

FIGURE 29: Outside and Ambient Combustion Air

GableVent

GasVent

SoffitVent

VentilatedAttic

Top AboveInsulation

OptionalInlet (a)

OutletAir (a)

VentilatedCrawl Space

GasWaterHeater F

urn

ace

SoffitVent

GasWaterHeater Inlet

Air (a)

InletAir (b) F

urn

ace

GasVent

OutletAir (a)

OutletAir (b)

InletAir (a)

InletAir (b)

GasWaterHeater F

urn

ace

VentilatedAttic

Top AboveInsulation

GableVent

GasVent

Johnson Controls Unitary Products 23

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SECTION VII: START-UP AND ADJUSTMENTS

NOx SCREEN REMOVAL (Lo-NOx Models Only)If the furnace is equipped with NOx screens and is to be used with LP(propane) gas, the screens must be removed prior to start-up.

1. Make sure that the electrical power to the unit is turned off and thatthe gas supply is turned off at the shut-off valve.

2. Remove the blower compartment and burner compartment accessdoors.

3. Disconnect the gas supply piping at the union to permit removal ofthe entire burner and gas control assembly from the vestibule panel.Use the wrench boss on the gas valve when removing or installingthe piping.

4. Unplug the igniter from the wire harness. Disconnect the flame sen-sor wires located on top of the air shield. Unplug the gas valve fromthe wiring harness.

5. Remove the screws holding the burner assembly to the vestibulepanel.

6. Remove the burner assembly. It should be possible to swing theburner assembly out of the way without disconnecting the remainingwires.

7. With the burner assembly out of the way, simply slide the NOxscreens out of the heat exchanger tubes and discard the screens.

8. Replace all components in reverse order. Reconnect all wiring.

GAS PIPING LEAK CHECK

It is recommended that when the gas supply is first connected to thefurnace, the ground union be loosened until the odor of gas is detected.When gas is detected, immediately tighten the union and check for gasleaks. Allow five minutes for any gas to dissipate before continuing withthe startup procedure. Be sure that proper ventilation is available todilute and carry away any vented gas.

With furnace in operation, check all of the pipe joints, gas valve connec-tions and manual valve connections for leakage using an approved gasdetector, a non-corrosive leak detection fluid or other leak detectionmethods. Take appropriate action to stop any leak. If a leak persists,replace the faulty component.

The furnace and its equipment shutoff valve must be disconnected fromthe gas supply during any pressure testing of that system at test pres-sures in excess of 1/2 PSI (3.45 kPa).

The furnace must be isolated from the gas supply piping system byclosing the equipment shutoff valve during any pressure testing of thegas supply system.

WARNINGCARBON MONOXIDE POISONING HAZARDFailure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon-monxide poisoning or death.The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliancesconnected to the venting system are not in operation:

1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or otherdeficiencies, which could cause an unsafe condition

2. Close all building doors and windows.3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum

speed. Open the fireplace dampers. Do not operate a summer exhaust fan.4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate contin-

uously.5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief open-

ing after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to theappliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for adowndraft or inadequate draft condition.

6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fire-place dampers and any other gas burning appliance to their normal condition.

7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does nothave enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance canfunction safely.

NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1 in. W.C. (-25 kPa) withall of the appliance(s) operating at the same time.

8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas CodeZ223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow theappropriate tables in Appendix G of the above codes or for this appliance.

!

NOTICEIn order that this furnace will operate properly, it is required that all ofthe startup procedures in this section be followed.

WARNINGFIRE OR EXPLOSION HAZARDFailure to follow the safety warnings exactly could result in seriousinjury, death or property damage.Never test for gas leaks with an open flame. Use a commerciallyavailable soap solution made specifically for the detection of leaks tocheck all connections. A fire or explosion may result causing propertydamage, personal injury or loss of life.

IMPORTANTBurner ignition may not be satisfactory on first startup due to residualair in the gas line or until gas manifold pressure is adjusted. The igni-tion control will make three attempts to light before locking out.

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SETUP TEST MODEDuring normal operation, the furnace input rate can vary between 50%and 100% of full nameplate input, making it difficult to check for properoperation. To help with the furnace startup process, the control has aTEST MODE available that allows the furnace input rate to stay at aconstant input rate. To access this TEST MODE perform the followingsequence:

1. With power to the board on and with no thermostat calls (no call forheating, cooling or continuous fan), push and hold the TEST buttonon the board for one second. The LED on the board will glow red.

2. Release the TEST button. The LED on the board will flash a rapidgreen signal, indicating that TEST MODE is activated.

3. Turn the thermostat to call for heat (R & W signal).

4. The furnace will light and operate at high (100%) firing rate. The fur-nace firing rate should be checked at this level to confirm that thefurnace is not overfired or underfired.

5. To run the furnace at minimum rate (50%), press the ERROR buttononce. The LED will flash one green flash to confirm.

6. To run the furnace at a middle rate (70%), press the ERROR buttontwice within a five-second period. The LED will flash green two timesto confirm.

7. To again operate the furnace at maximum (100%) rate, press theERROR button three times within a five-second period. The LED willflash green three times to confirm.

8. If the thermostat call for heat is removed, the LED will flash a rapidgreen signal, indicating that the furnace is still in TEST MODE.

9. When startup tests are completed, turning off power to the board willtake the furnace out of TEST MODE and will restore normal opera-tion. The furnace will automatically return to normal operation after150 minutes if power is not cycled.

CALCULATING THE FURNACE INPUT (NATURAL GAS)

Verify natural gas input rate by clocking meter.

1. Turn off all other gas appliances and pilots.

2. Run furnace for a minimum of 3 minutes in heating operation.

3. Measure time (in sec) for gas meter to complete 1 revolution andnote reading. The 2 cubic feet dial provides a more accurate mea-surement of gas flow.

4. Refer to Table 10 for cubic feet of gas per hour.

5. Multiply cubic feet per hour by heating valve (BTU/cu ft) to obtaininput.

If clocked rate does not match the input rate from the unit nameplate.follow steps in next section to adjust the manifold pressure. Repeatsteps 2 - 5 until correct input is achieved.

HIGH ALTITUDE NATURAL GAS ORIFICE CONVERSIONThe National Fuel Gas Code requires that gas appliances installedabove 2,000 feet elevation have their inputs de-rated by 4% per 1,000feet above sea level. The modulating furnaces automatically de-rate foraltitude by measuring the inducer blower pressure and using that todetermine if there is adequate air to support good combustion. If thereis not enough combustion air to properly support 100% of the furnacenameplate input rate, the control will reduce the input to the point thatthere will be good combustion.

NOTICEBurner orifices are sized to provide proper input rate using naturalgas with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heatingvalue of your gas is significantly different, it may be necessary toreplace the orifices.

NOTICEDO NOT set manifold pressure less than 3.2 in wc or more than 3.8 inwc for natural gas at sea level. If manifold pressure is outside thisrange, change main burner orifices.

CAUTIONDO NOT bottom out gas valve regulator adjusting screw. This canresult in unregulated manifold pressure and result in excess overfireand heat exchanger failures.

NOTICEIf orifice hole appears damaged or it is suspected to have beenredrilled, check orifice hole with a numbered drill bit of correct size.Never redrill an orifice. A burr-free and squarely aligned orifice hole isessential for proper flame characteristics.

CAUTIONBe sure to relight any gas appliances that were turned off at the startof this input check.

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Table 10: Gas Rate (CU FT/HR) at Full Input

Seconds For 1 Revolution

Size of Test Dial Seconds For 1 Revolution

Size of Test Dial1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft

10 360 720 1800 55 65 131 327

11 327 655 1636 56 64 129 321

12 300 600 1500 57 63 126 316

13 277 555 1385 58 62 124 310

14 257 514 1286 59 61 122 305

15 240 480 1200 60 60 120 300

16 225 450 1125 62 58 116 290

17 212 424 1059 64 56 112 281

18 200 400 1000 66 54 109 273

19 189 379 947 68 53 106 265

20 180 360 900 70 51 103 257

21 171 343 857 72 50 100 250

22 164 327 818 74 48 97 243

23 157 313 783 76 47 95 237

24 150 300 750 78 46 92 231

25 144 288 720 80 45 90 225

26 138 277 692 82 44 88 220

27 133 267 667 84 43 86 214

28 129 257 643 86 42 84 209

29 124 248 621 88 41 82 205

30 120 240 600 90 40 80 200

31 116 232 581 92 39 78 196

32 113 225 563 94 38 76 192

33 109 218 545 96 38 75 188

34 106 212 529 98 37 74 184

35 103 206 514 100 36 72 180

36 100 200 500 102 35 71 178

37 97 195 486 104 35 69 173

38 95 189 474 106 34 68 170

39 92 185 462 108 33 67 167

40 90 180 450 110 33 65 164

41 88 176 439 112 32 64 161

42 86 172 429 116 31 62 155

43 84 167 419 120 30 60 150

44 82 164 409 124 29 58 145

45 80 160 400 128 28 56 141

46 78 157 391 133 27 54 135

47 76 153 383 138 26 52 130

48 75 150 375 144 25 50 125

49 73 147 367 150 24 48 120

50 72 144 360 157 23 46 115

51 71 141 355 164 22 44 110

52 69 138 346 171 21 42 105

53 68 136 340 180 20 40 100

54 67 133 333

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ADJUSTMENT OF MANIFOLD GAS PRESSUREInlet and manifold gas pressure may be measured by connecting the“U” tube manometer to the gas valve with a piece of tubing. Follow theappropriate section in the instructions below. Refer to Figure 30 for adrawing of the locations of the pressure ports on the gas valve.

Turn gas off at the ball valve or gas cock on gas supply line before the gas valve. Find the pressure ports on the gas valve marked Out P and In P.1. The manifold pressure must be taken at the port marked OUT P.

2. The inlet gas line pressure must be taken at the port marked IN P.

3. Using a 3/16” allen wrench, remove the plugs from the inlet and out-let pressure ports. Connect a 1/8” UPT barbed hose fitting to eachpressure port.

4. Refer to Figure 30 for location of pressure regulator adjustment capand adjustment screws on main gas valve.

5. Turn gas and electrical supplies on and follow the operating instruc-tions to place the unit back in operation.

6. Remove the small plastic cap to gain access to the regulator adjust-ment screw.

7. Use a small slotted screwdriver to turn the regulator adjustmentscrew. Adjust the pressure by turning the screw one click at a timeuntil desired pressure is reached. Wait a few seconds after eachadjustment to allow the pressure to stabilize before making addi-tional adjustments. This is an electronic adjustment screw that doesnot require very much force. Application of excessive force to theadjustment screw will damage the gas valve.

8. After the manifold pressure has been adjusted, re-calculate the fur-nace input to make sure you have not exceeded the specified inputon the rating plate. Refer to "CALCULATING THE FURNACE INPUT(NATURAL GAS)".

9. Once the correct BTU (kW) input has been established, turn the gasvalve to OFF and turn the electrical supply switch to OFF; thenremove the flexible tubing and fittings from the gas valve pressuretap replace the pressure tap plugs.

10.Turn the electrical and gas supplies back on, and with the burners inoperation, check for gas leakage around the gas valve pressure portfor leakage using an approved gas detector, a non-corrosive leakdetection fluid, or other leak detection methods.

ADJUSTMENT OF TEMPERATURE RISE

After about 5 minutes of operation, determine the furnace temperaturerise. Take temperature readings of both the return air and the heated airin the ducts about six feet away from the furnace, where they will not beaffected by radiant heat. Increase or decrease the temperature rise bychanging the ATR jumper on the furnace control board. The jumper isfactory-set to deliver an air temperature rise near the midpoint of thenameplate temperature rise range. If more air is desired (lower tem-perature rise), move the jumper to the -10 position. If less air is desired(higher temperature rise), move the jumper to the +10 position.

Table 11: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGENatural Gas Propane (LP)

Minimum* 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa)

Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa)

IMPORTANTThe inlet gas pressure operating range table specifies what the mini-mum and maximum gas line pressures must be for the furnace tooperate safely. The gas line pressure MUST BE a minimum of:

• 7” w.c. (1.74 kPA) for Natural Gas• 11” w.c. (2.74 kPA) for Propane (LP) Gas

in order to obtain the BTU input specified on the rating plate and/orthe nominal manifold pressure specified in these instructions and onthe rating plate.

IMPORTANTThe cap for the pressure regulator must be removed to gain access tothe adjustment screw.

NOTICEThe regulated outlet pressure has been calibrated at the factory.Additional pressure adjustment should not be necessary. If adjust-ment is necessary, set to the following specifications. After adjust-ment, check for gas leakage.

TABLE 12: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURENatural Gas (Max) 3.5" w.c. (0.87 kPa)

Natural Gas (Min) 0.5" w.c. (0.15 kPa)

Propane (LP) Gas (Max) 10.0" w.c. (2.49 kPa)

Propane (LP) Gas (Min) 1.6" w.c. (0.40 kPa)

FIGURE 30: Gas Valve

IMPORTANTIf gas valve regulator is turned clockwise, manifold pressure isincreased. If screw is turned counterclockwise, manifold pressure willdecrease. The adjustment screw has a range of 16 clicks (about ±0.5” manifoldpressure). There is not a hard stop at the ends of the adjustmentrange. When the limit of the adjustment range is reached, the nextclick will start over at the other end of the range. For instance, if youare increasing pressure and reach the upper limit of adjustment thenext click will drop the pressure to the lower limit.

DANGERThe temperature rise, or temperature difference between the returnair and the supply (heated) air from the furnace, must be within therange shown on the furnace rating plate and within the applicationlimitations shown in Table 6.The supply air temperature cannot exceed the “Maximum SupplyAir Temperature” specified in these instructions and on the furnacerating plate. Under NO circumstances can the furnace be allowed tooperate above the Maximum Supply Air Temperature. Operating thefurnace above the Maximum Supply Air Temperature will cause pre-mature heat exchanger failure, high levels of Carbon Monoxide, a firehazard, personal injury, property damage, and/or death.

InletPressureTap

OutletPressureTap

On/OffSwitch

MainRegulatorAdjustment

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ADJUSTMENT OF FAN CONTROL SETTINGSCooling - The airflow delivered by the furnace during cooling operationcan be adjusted to match the cooling capacity of the A/C condensingunit. This is done by moving the COOL and ADJ jumper on the controlboard to give the desired airflow.

The COOL jumper has four positions, which will deliver sufficient airflowin cooling mode for the cooling capacities shown in Table 13.

the ADJ jumper has three positions which can be used to make furtheradjustments to the cooling blower airflow.

Continuous Fan Operation - The airflow delivered by the furnaceduring continuous fan operation can be adjusted as desired. This isdone my moving the control fan jumper on the control board to give thedesired airflow.

The jumper has three positions. The “H” position delivers maximum air-flow, 100% of the blower capacity. Position “M” delivers approximately70% of the blower capacity. And Position “L” delivers minimum airflow,approximately 40% of the blower capacity.

FIGURE 31: Furnace Control Board

LowVoltageTerminals

HumidistatJumper

LastError Button

TestButton

ContinuousFan SpeedJumper

Cooling SpeedJumper

Heat PumpJumper

ZoningJumper

EACTerminalsHumidifier

Terminals

DiagnosticLight

28 Johnson Controls Unitary Products

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All CFMs are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0” to 0.6” w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than 1.0” w.c. external static pressure is not recommended.

NOTE: At some settings, LOW COOL airflow may be lower that what is required to operate an airflow switch on certain models of electronic air cleaners. Con-sult the instructions for the electronic air cleaner for further details.

Table 13: Blower Performance CFM - Any Position

High / Low Speed Cooling CFM 060A12 080B12 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

1340 900 1290 790 H B

1125 750 1065 660 MH B

1225 820 1165 720 H A

1050 680 960 600 MH A

1100 740 1050 590 H C

890 600 855 525 ML B

920 615 875 540 MH C

675 450 640 395 L B

815 545 775 495 ML A

600 440 580 380 L A

720 499 700 430 ML C

540 440 525 380 L C

High / Low Speed Cooling CFM 080C16 100C16 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

1715 1165 1600 1120 H B

1520 1020 1450 980 MH B

1575 1060 1500 1020 H A

1395 930 1345 900 MH A

1430 950 1315 930 H C

1320 875 1265 845 ML B

1260 840 1210 805 MH C

1100 730 1080 700 L B

1200 795 1165 765 ML A

1000 665 980 635 L A

1080 715 1050 695 ML C

900 600 885 585 L C

High / Low Speed Cooling CFM 100C20 120C20 Jumper Settings

Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper

2110 1360 1990 1290 H B

1670 1085 1760 1030 MH B

1900 1235 1900 1210 H A

1515 990 1510 935 MH A

1710 1130 1800 1095 H C

1465 950 1540 900 ML B

1370 890 1440 845 MH C

1255 815 1320 790 L B

1330 865 1400 835 ML A

1140 740 1200 725 L A

1195 780 1260 750 ML C

1025 665 1080 650 L C

Johnson Controls Unitary Products 29

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Delay Taps SelectionThe set of jumper pins on the control board labeled “DELAY” are usedto set the delay profiles for the furnace. These can be chosen so as tomaximize the comfort and sound levels for various regions of the coun-try.

Tap A is the default profile. It provides a 30-second ramp-up from zeroairflow to full capacity and a 30-second ramp-down from full capacityback to zero airflow. Whenever there is a change in airflow mode, suchas from low heat to high heat, the motor will take 30 seconds to rampfrom one speed to the other.

Tap B is the humid profile. This profile is best-suited for installationswhere the humidity is frequently very high during cooling season, suchas in the southern part of the country. On a call for cooling, the blowerwill ramp up to 50% of full capacity and will stay there for two minutes,then will ramp up to 82% of full capacity and will stay there for five min-utes, and then will ramp up to full capacity, where it will stay until thewall thermostat is satisfied. In every case, it will take the motor 30 sec-onds to ramp from one speed to another.

Tap C is the dry profile. This profile is best suited to parts of the countrywhere excessive humidity is not generally a problem, where the sum-mer months are usually dry. On a call for cooling the motor will ramp upto full capacity and will stay there until the thermostat is satisfied. At theend of the cooling cycle, the blower will ramp down to 50% of full capac-ity where it will stay for 60 seconds. Then it will ramp down to zero. Inevery case, it will take the motor 30 seconds to ramp from one speed toanother.

Tap D is the normal profile, best suited for most of the country, whereneither excessive humidity nor extremely dry conditions are the norm.On a call for cooling, the motor will ramp up to 63% of full capacity andwill stay there for 90 seconds, then will ramp up to full capacity. At theend of the cooling cycle, the motor will ramp down to 63% of full capac-ity and will stay there for 30 seconds, then will ramp down to zero. Inevery case, it will take the motor 30 seconds to ramp from one speed toanother.

HumidistatWhen a humidistat is installed in the system, the “Humidistat” jumper onthe control board should be moved to the “YES” position. The coolingairflow will then be reduced by 15% whenever the humidistat indicateshigh humidity.

SECTION VIII: SAFETY CONTROLSCONTROL CIRCUIT FUSEA 3-amp fuse is provided on the control circuit board to protect the 24-volt transformer from overload caused by control circuit wiring errors.This is an ATO 3, automotive type fuse and is located on the controlboard.

BLOWER DOOR SAFETY SWITCHThis unit is equipped with an electrical interlock switch mounted in theburner compartment. This switch interrupts all power at the unit whenthe panel covering the blower compartment is removed.

Electrical supply to this unit is dependent upon the panel that covers theblower compartment being in place and properly positioned.

ROLLOUT SWITCH CONTROLSThese controls are mounted on the burner assembly. If the temperaturein the burner area exceeds its set point, the ignition control and the gasvalve are de-energized. The operation of this control indicates a mal-function in the combustion air blower, heat exchanger or a blocked ventpipe connection. Corrective action is required. These are manual resetcontrols that must be reset before operation can continue.

PRESSURE CONTROLSPressure Sensor - This furnace is equipped with a pressure sensor inthe burner compartment near the combustion blower. This sensor mon-itors combustion airflow through furnace and piping systems. If any ofthe conditions listed below are detected by the pressure sensor, thecontrol board will prevent a hazardous condition from occurring byspeeding up the combustion blower motor in order to maintain ade-quate combustion airflow. If the combustion blower is already turning atfull speed, the furnace control will then start reducing the input to thefurnace in order to maintain proper combustion with the amount of com-bustion airflow available. If there is not enough combustion air availableto give proper combustion even at the minimum input rate (50%), thecontrol will close the gas valve and shut off the burners. The sensor willdetect the following conditions.

1. Blockage of vent piping or vent terminal

2. Failure of combustion air blower motor or blower wheel.

Pressure Switch - This furnace is equipped with a pressure switchmounted on the furnace vestibule panel. This switch monitors the flowthrough the vent system. The switch will close at the beginning of eachcycle when adequate combustion airflow is established. However, thisswitch may be open under certain conditions when the burners are lit.The pressure sensor is the primary flow sensor.

LIMIT CONTROLSLimit Switch - This furnace is equipped with a high temperature limitcontrol mounted to the left side of the furnace vestibule panel. This limitswitch will open and shut off gas to the burners if it detects excessive airtemperature in the furnace, which can be caused by any of the followingconditions:

1. Dirty filter

2. Failure of the circulating blower motor or wheel

3. Too many supply or return registers closed or blocked.

Temperature Sensor - This furnace is also equipped with a tempera-ture sensor mounted to the left side of the vestibule panel, near the limitswitch. This sensor monitors the temperature of the air being suppliedto the home. If the sensor detects air temperature higher than normal,the furnace control will first speed up the circulating blower motor inorder to try to increase the amount of airflow being delivered, therebyreducing the air temperature. If the blower motor is already turning atfull speed, the control will then start reducing the input to the furnace totry to reduce the air temperature. If the supply air temperature is toohigh even at the minimum input rate (50%), the control will close thegas valve and shut off the furnace.

CAUTIONMain power to the unit must still be interrupted at the main power dis-connect switch before any service or repair work is to be done to theunit. Do not rely upon the interlock switch as a main power discon-nect.Blower and burner must never be operated without the blower panelin place.

!

30 Johnson Controls Unitary Products

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SECTION IX: NORMAL OPERATION AND DIAGNOSTICSNORMAL OPERATION SEQUENCEThe furnace control calculates the optimum firing rate each time thewall thermostat R and W contacts close or open (at the beginning andat the end of each call for heat) based on information from the thermo-stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THEWALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ONAND OFF. THE FURNACE CONTROL CALCULATES THE DEMANDAND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONSOF THE THERMOSTAT “OFF” CYCLE.

When the wall thermostat R and W contacts close, indicating a call forheat, the following sequence occurs:

1. The inducer is energized and ramps up its speed until airflow isproven by the pressure switch and by the pressure sensor on thecontrol board.

2. The hot surface ignitor is energized.

3. After a 17-20 second igniter heat-up, the gas valve opens and theburners light.

4. When the control senses that flame is present, the circulating blowerstarts at low speed.

5. The furnace fires at 70% of full rate for 30-45 seconds, then drops tothe minimum (50%) firing rate. If chimney kit S1-1CK0605 is used,the minimum firing rate is restricted and adjusted to 65% of full rate.

6. The firing rate is automatically adjusted to meet demand, increasinggradually to maximum (100%) firing rate if the thermostat is not sat-isfied within a defined time.

7. When the thermostat R and W contacts open (thermostat is satis-fied) the furnace control recalculates the demand and a new firingrate. a. If demand exceeds the minimum firing rate, the burners will con-

tinue to fire at a recalculated reduced firing rate, decreasing if thethermostat remains off for a defined time.

b. If demand does not exceed the minimum firing rate, the burnerswill shut off immediately.

8. After the burners shut off, the circulating blower will continue to rununtil the temperature sensor detects that the supply air temperaturehas dropped to the desired level, which should take from 30 to 90seconds.

FURNACE CONTROL DIAGNOSTICSThis furnace has built-in self-diagnostic capability. If a system problemoccurs, a flashing LED shows a fault code. The LED can flash red,green or amber to indicate various conditions. The LED is located onthe furnace control board and can be seen through the clear view portin the lower door of the furnace. To indicate an error condition, the LEDwill turn on for 1/4 second and off for 1/4 second. The pattern will berepeated the number of times equal to the flash code. For instance, a“six flash code” will be indicated by the LED turning on and off six times.There will be a two second off period between each set of flashes. Theflash codes and an indication of their likely causes are listed below:

STEADY OFF - No 24V power to board. Check the 24 volt control cir-cuit fuse on the board. Check the circuit breaker or fuse on the 115 voltsupply power to the furnace. Check that the 24 volt transformer.

One Green Flash - Normal Operation with no call for heat.

Two Green Flashes - Indicator for “No error codes in memory”. SeeDiagnostic Fault Code Storage and Retrieval section below.

Three Green Flashes - Indicator for “Error codes cleared from mem-ory”. See Diagnostic Fault Code Storage and Retrieval section below.

Rapid Green Flash - Control is in “Factory Speed-up” mode. Thismode is used only during factory run-testing of the furnace. To stop thismode, cycle power to the furnace off and then back on.

One Amber Flash - Normal operation with call for cooling.

Two Amber Flashes - Normal operation with call for heat.

Three Amber flashes - Normal operation, burner is on at end of heat-ing cycle after wall thermostat has been satisfied.

Four Amber Flashes - Heating capacity is reduced due to restriction inthe circulating air system. Check for dirty filter or closed registers.

Five Amber Flashes - Heating capacity is reduced due to restriction inthe combustion air or vent system. Check for blocked vent/air pipe orclogged condensate drain. Above 4,000 feet altitude, this may also indi-cate automatic, normal derating for altitude. See page 7 for additionalhigh altitude information.

Six Amber Flashes - (Heat Pump applications only) Normal operationwith call for heat pump heating.

Seven Amber Flashes - Normal operation, air conditioning, compres-sor is on in low cooling after wall thermostat has been satisfied.

Rapid Amber Flash - Low flame sense current. Check for dirty or mis-located flame sensor rod.

One Red Flash - Flame is present with no power being supplied to gasvalve. This can be caused by a gas valve that is slow to close or thatleaks gas through to the burners.

Two Red Flashes - Pressure switch closed with inducer pressurebelow pressure switch setpoint (switch is closed when it should beopen). Check pressure switch.

Three Red Flashes - Pressure switch open with inducer pressureabove pressure switch setpoint (switch is open when it should beclosed). Check pressure switch.

Four Red Flashes - High limit switch open or defective temperaturesensor or 24 volt fuse is open. This may be caused by a dirty air filter,improperly sized duct system, faulty blower motor, restricted circulatingairflow an open fuse on the control board.

Five Red Flashes - Rollout switch or condensate pressure switchopen. Check the rollout switch(es) on the burner assembly. It is a man-ual reset switch. To reset, push the small button in the center of theswitch. If it cannot be reset or if the switch trips again, contact a quali-fied serviceman.

Six Red Flashes - Current failure on modulating gas valve.

Seven Red Flashes - Lockout due to no ignition. The control will trythree times for ignition. If flame cannot be established in three tries, thecontrol will lockout for one hour and then will try again to light. Checkgas supply, ignitor, gas valve, flame sensor.

Eight Red Flashes - Lockout due to too many flame recycles. Thisflash code occurs if flame is lost five times during a single heating cycle.This could be caused by a faulty gas valve, low gas pressure, or dirtyflame sensor. The control will lock out for one hour and then will tryagain.

Nine Red Flashes - Reversed line polarity or improper grounding.Check polarity of the incoming power to the furnace. Check the ground-ing of the furnace, including the transformer ground and the L1 andneutral connections.

Ten Red Flashes - Gas valve circuit shorted. Check gas valve wiring. Ifcorrect, replace gas valve.

Eleven Red Flashes - Main blower failure - This flash code occurswhen the main limit opens and fails to reclose within five minutes, indi-cating that the blower motor or blower wheel has failed.

Twelve Red Flashes - ID plug is not present or not connected properly,check for loose plug or loose wires in plug.

Steady On Red - Control fault has been detected or there is 115 voltspresent without 24 volts. Check whether there is 24 volts and 115 voltsbeing supplied to the board. If not, correct the voltage problem. If thereis both 24 and 115 voltage to the board, replace the control board.

IGNITION CONTROL FLAME SENSE LEVELSNormal flame sense current is approximately

3.7 microamps DC (μa)Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is0.1 microamps DC (μa)

Johnson Controls Unitary Products 31

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DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVALThe control in this furnace is equipped with memory that will store up tofive error codes to allow a service technician to diagnose problemsmore easily. This memory will be retained even if power to the furnaceis lost. Only a qualified service technician should use this feature.The control stores up to five separate error codes. If more than fiveerror codes have occurred since the last reset, only the five most recentwill be retained. The furnace control board has a button, labeled “LASTERROR” that is used to retrieve error codes. This function will onlywork if there are no active thermostat signals. So any call for heating,cooling or continuous fan must be terminated before attempting toretrieve error codes.

To retrieve the error codes, push the LAST ERROR button. The LEDon the control will then flash the error codes that are in memory, startingwith the most recent. There will be a two-second pause between eachflash code. After the error codes have all been displayed, the LED willresume the normal slow green flash after a five second pause. Torepeat the series of error codes, push the button again.

If there are no error codes in memory, the LED will flash two greenflashes. To clear the memory, push the LAST ERROR button and holdit for more than five seconds. The LED will flash three green flasheswhen the memory has been cleared, then will resume the normal slowgreen flash after a five-second pause.

SECTION X: REPLACEMENT PARTS LISTDESCRIPTION

MOTORMOTOR, DIRECT DRIVE BLOWER

BLOWER, COMBUSTION

ELECTRICALCAPACITOR, RUN

SWITCH, LIMIT

CONTROL, FURNACE

IGNITER

SENSOR, FLAME

SWITCH, PRESSURE

SWITCH, DOOR

TRANSFORMER

VALVE, GAS

CONTROL, TEMPERATURE

SENSOR, PRESSURE

SENSOR, THERMISTOR

AIR MOVINGHOUSING, BLOWER

WHEEL, BLOWER

FABRICATED PARTSBAFFLE, FLUE

BURNER, MAIN GAS

BRACKET, IGNITER

SHELF, BLOWER

RAIL, BLOWER (2 Req’d)

FABRICATED PARTS ContinuedBRACKET, BLOWER TRACK (2 Req’d)

HEAT EXCHANGER ASS’Y

MANIFOLD, GAS

PAN, BOTTOM

PANEL, TOP

PANEL, DOOR (2 Req’d)

VENT PAN, COMBUSTION (w/Gasket)

PANEL, BLOCKOFF

LO-NOX SCREEN (L-Models Only)

MISCELLANEOUSORIFICE, BURNER (Natural #45)

SIGHT GLASS, OVAL (2 Req’d)

GASKET, FOAM (Door) (1.5 ft req’d)

GASKET, INTAKE PAN

PLUG, VENT HOLE

BRACKET, DOOR

WIRING HARNESS

FERRULE (3 Req’d)

GROMMET (3 Req’d)

MOTOR MOUNT

HOSE ASSY, VACUUM

PLUG, ID (Control Board)

KNOB, QUARTER TURN (4 Req’d)

UNION

DIAGRAM, WIRING

DESCRIPTION

REPLACEMENT PART CONTACT INFORMATIONThis is a generic parts list. To request a complete parts list, refer to the contact information below:

• Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.

a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

• You can contact us by mail. Just send a written request to:Johnson Controls Unitary Products

Consumer Relations5005 York Drive

Norman, OK 73069

32 Johnson Controls Unitary Products

Page 33: INSTALLATION MANUAL - Johnson Controls

987158-UIM-D-0616

SECTION XI: WIRING DIAGRAM

FIGURE 32: Wiring Diagram

Wiring Diagram 80+% Modulating Furnace With ECM Motor

GAS VALVE

TO AIR CONDITIONERCONTROLS

ROOMTHERMOSTAT COMMON T'STAT CONNECTION

Y2Y

R

C

G

Y1

W W

Y1

G

C

R

YY2

VENTORMOTOR

EAC

HUMIDIFIER

BLOWER

MOTOR

POWER SUPPLY 115-1-60 SEE NOTE 1

GND(EN TERRE)

CNO

HSI

NO

PSC

GRD

COM120V

24V SEC

PRIXFMR (40VA)

LS ROS1 ROS2

BLK

24V

120V

CO

MG

RN

WHT

GASVALVE

WHT

WHT2

1

GRN

BLKBLKWHT

INTEGRATEDCONTROL BOARD

RED/GRNRED/GRN

RED

BLU

BRN

TAN

TAN

GRY

GRY

PRP

HSI

VENTORMOTOR

FLAMESENSOR

LS

NO C DOOR SWITCH

115VAC LINE

115VAC NEUT.

ID P

LUG

1

2

40 V

AX

FMR

HUM

EAC

ORGORGNO C

PS

ID PlugsLO COMPHI COMPODHUMY1Y/Y2WRGC

120VAC NEUTRAL

GROUND

120VACXFORMER

NEUTRALXFORMER

MOTOR MOTOR

FUS

E

HUM

NEUTRAL

NEUTRAL

NEUTRAL

NEUTRAL

HOTEACHOT

HOT

HOT

IGNITER

INDUCER

EAC

FLAME ROD

24VAC

GN

D

GA

S

PRIM LIMITAUX LIMIT

998911-UWD-A-0213

EXTPRESSURESENSOR

RE

D/W

HT

BLK

/WH

TG

RN

/WH

T

PRESSURESENSOR

GR

NB

LK

RE

D

120VACLINE LINE

NEUTRAL

THERMISTERBLKBLK12 RED/BLK

RED/BLK

TEMPERATURESENSOR

MOTOR CONNECTOR

(1)G

RN

(8)G

RN

(3)G

RN

(12)

BR

N

(10)

BLK

(9)B

RN

(15)

BLU

/WH

T(1

6)Y

EL/

BLK

BLK

WHT

BLK

GR

N

PF (NOT USED ON 1/2 HP MOTORS)

BLK

BLK

BLK

PF (NOT USED ON 1/2 HP MOTORS)

WHT

BLK

AIR SW

GN

DTX R

XH

OT

HO

T24

VA

C

OU

TG

ND

VC

C

123

456

1346782

5

ROS1ROS2RED RED

YELGRN

REDBLU/WHT

ORG TH RXD TXD TRMV TH

1 2 3

3 2 1

12345

Power OffNormal OperationLow flame sense currentNormal Operation with call for coolingNormal Operation with call for heatNormal Operation, burner on at end of heat cycleReduced Airflow problemHigh altitude installation OR vent, ORtermination problemNormal Operation with call for heat pump heatingControl FailureFlame present with gas offCheck pressure switch wiringVent OR termination problemAirflow problem OR open fuseFlame RolloutCheck gas valve wiringFailed to light burnersLoss of flame during call for heatHot/Neutral reversed OR poor ground/neutralGas valve shorted "ON"Check blower motor/wiringID plug missing or not connected properly

Flashes

Diagnostic Fault Codes

Fault ConditionNone1 Slow GreenRapid Amber1 Amber2 Amber3 Amber4 Amber5 Amber 6 AmberSteady on Red1 Red2 Red3 Red4 Red5 Red6 Red7 Red8 Red9 Red10 Red11 Red12 Red

SERVICING THIS UNITOPEN ALL DISCONNECTS BEFORE

CAUTION

PRECAUTIONOUVREZ LES DISJONCTEURS AVANTDE PROCEDER AVEC LE SERVICE

DS -ROS1 -ROS2 -XFMR -HSI -PF-PS -EAC -LS -HUM -

LegendDoor SwitchRoll Out SwitchRoll Out SwitchTransformerHot Surface igniterPower Factor chokePressure SwitchElectronic Air CleanerLimit switchHumidifierFactory Wiring and DevicesField Wiring and Devices

DS -ROS1 -ROS2 -XFMR -HSI -PF - PS -EAC-LS -HUM -

LegendeCommutateur de porteCommutateur de roulementCommutateur de roulementTransformeurIgnition de surface chaudTransformeur de facteurde puissanceCommutateur de pressionFiltre électriqueCommutateur de limiteHumidificateurFilage de l'usine et appareilsFilage de chantier et appareils

NOTES:1. Si l'un des fils d'origine fourni avec ce four doit filage doit être remplacé, il doit être remplacé avec le fil ayant un degré de température d'au moins 221 degrés F (105 degrés C ). 2. Seulement des marettes pour fil de cuivre.

NOTES:1. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 221 degrees F (105 degrees C).2. Connectors suitable for copper conductors only.

Fault Code RetrievalNotice - Only a qualified service technician should use this feature.Fault code retrieval functions will work only if there are no active thermostat signals.To retrieve fault codes, push and release ERROR button on control board. The LED will flash the last five error codes, beginning with the most recent. If there are no fault codes in memory, the LED will give two green flashes. To clear thefault code memory, push and hold the ERROR button for at least five seconds. The LED will give three green flashes when the memory has been cleared.

Note to ServicersUnlike conventional systems, the wall thermostat does not simply turn this furnace off and on. The furnace control calculates the demand and THE FURNACE BURNERS MAY CONTINUE TOFIRE DURING PART OF THE THERMOSTAT "OFF" CYCLE.Refer to the furnace instructions for further information.

Model Colors

60A12 BRN/WHT

80B12 RED/WHT

80C16 BLU/WHT

100C16 BLK/WHT

100C20 GRN/WHT

120C20 PUR/WHT

Johnson Controls Unitary Products 33

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987158-UIM-D-0616

NOTES

34 Johnson Controls Unitary Products

Page 35: INSTALLATION MANUAL - Johnson Controls

987158-UIM-D-0616

SECTION XII: START UP SHEET

Water Heater BTUH Input Fan Assisted?

33" 80% AFUE (ECM/PSC) Modulating Gas Furnace Start Up Sheet Proper furnace start up is critical to customer comfort and equipment longevity

Name Address

City State or Province Zip or Postal Code

Furnace Model Furnace Serial

Evaporator Coil Model Evaporator Coil Serial

Upflow Downflow Horizontal Left Horizontal Right

Unit is level

Venting system is the proper size, within the limitations of the chart in the

installation instructions, properly connected to the furnace, and properly pitched

Filter Type

Connector Size Connector Length

# 0f 45 Degree Ells# of 90 Degree Ells

Polarity is correct (black is L1 (hot), white is N (neutral) Ground wire is connected Line voltage to furnace (AC)

Low voltage value between "R" and "C" on furnace control board (volts AC)

Thermostat Type Other System Equipment and Accessories

Owner Information

Equipment Data

Furnace Configuration

Venting: B Vent

Electrical: Line Voltage

Outdoor Unit Model Outdoor Unit Serial

Filter, Thermostat, Accessories

Filter Location(s)

Connections -- All Per Installation Instructions and Local CodeGas piping is connected (including drip leg) Supply plenum and return air are connected

Filter Size

Vent system is connected

Thermostat wiring is complete

Electrical: Low Voltage

Technician Performing Start-Up Installing Contractor Name

Start-Up Date

Continued on next Page

Connector Length

# 0f 45 Degree Ells# of 90 Degree Ells

Connector Size

Venting: Lined Masonry Chimney with B-Vent Connector

Other appliances in same common vent:

Vent Pipe Size

Furnace BTUH Input Fan Assisted?

Other BTUH Input Fan Assisted?

Total Height

Chimney Height

Y N

NY

Y N

Thermostat cycle rate set to 6 cycles/hour (if present)

Thermostat heat anticipator set to .1 (if present)

Johnson Controls Unitary Products 35

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Other Jumpers De-humidistat Heat Pump Zone Control

Natural Gas LP Gas (Requires LP conversion kit)

LP Conversion Kit Installed By

Supply static after evaporator coil (in w.c.")

Return Static (in w.c.") before filter

Total External Static Pressure

Temperature Rise in Degrees F

Installation debris disposed of and furnace area cleaned up?

Explain operation of system to equipment owner

ATR Setting

Blower Speed Selected L (Low) M (Med) H (High)

Explain the importance of regular filter replacement and equipment maintenance

Gas Side

Air Side: System External Static Pressure (Cooling Mode)

Owner Education

Additional Job Detail

Supply static before evaporator coil (in w.c.")

Calculated input in btuh - clock the gas meter (Nat Gas Only)

Manifold Gas Pressure (in. w.c.") - furnace must be in TEST Mode for setupInlet Gas Pressure (in. w.c.")

LP Gas Conversion Kit Part # Used

Burner flame inspected -- flames are blue and extending directly into the primary heat exchanger cells

Return Static (in w.c.") after filter (furnace side)

Air Side: Heating

Air Side: Continuous Fan

Clean Up

Give owner the owner's manual provided

Gas Type

Explain thermostat use and programming (if applicable) to owner

Cycle TestOperate the furnace through several heating cycles from the thermostat, noting and correcting any problems

Operate the furnace through continuous fan cycles from the thermostat, noting and correcting any problems

Operate the furnace through cooling cycles (as applicable), noting and correcting any problems

NOYES

NOYES

YES NO+10FNOM -10F

L (Low) ML (Med Low) MH (Med High) H (High)

C B A

L (Low) ML (Med Low) MH (Med High) H (High)DELAY Setting (ECM Models)

ADJUST Setting (ECM Models)

COOL Speed SelectedAir Side: Cooling

Subject to change without notice. Published in U.S.A. 987158-UIM-D-0616Copyright © 2016 by Johnson Controls, Inc. All rights reserved. Supersedes: 987158-UIM-C-0715

York International Corp.5005 York Drive

Norman, OK 73069